Resonant oscillating scanning device with multiple light sources and dual scan path

ABSTRACT

An optical scanning system including a resonant oscillating device having a first magnetic field and a mirrored surface. The system includes first and second light sources for directing first and second beams of light to the mirrored surface of the resonant oscillating device to provide first and second reflected scan beams. The second reflected scan beam is offset a first distance from the first reflected scan beam. A second magnetic field is included for interacting with the first magnetic field to provide torque to the resonant oscillating device for scanning the first and second reflected scan beams across a surface to provide first and second scan lines on the surface substantially simultaneously as the resonant oscillating device oscillates under the influence of the first and second magnetic fields. The optical scanning system is effective to increase scan efficiency of the resonant oscillating device over that of a system using a single light source.

This application is a divisional of application Ser. No. 10/629,816filed Jul. 29, 2003 now U.S. Pat. No. 7,064,876, entitled ResonantOscillating Scanning Device with Multiple Light Sources.

FIELD OF THE INVENTION

The present invention is generally directed to scanning systems. Moreparticularly, the invention is directed to an apparatus and method usingmultiple light beams.

BACKGROUND AND SUMMARY OF THE INVENTION

Resonant torsion oscillators are known, however, they are not widelyused in imaging devices such as laser printers. One problem withoscillators in scanners is that the scan efficiency of such a typicalgalvo device is substantially less than that of a rotating polygonmirror conventionally used for such laser scanning procedures. Otherproblems associated with torsion oscillators include bulk associatedwith the materials used for the springs, magnets and coils; frequencydrift; and instability. In general, these problems and others haveprevented or discouraged use of torsion oscillators in applications suchas optical systems.

There is a need, therefore, for an improved galvo device havingincreased scanning efficiency. There is also a need for a scanningdevice having a scanning efficiency approaching or exceeding that of arotating polygon mirror.

Oscillating devices may be etched or cut as a micro-electromechanicalsystem (MEMS) device, preferably from a single piece of silicon. TheMEMS device provides a small, relatively compact device that can beilluminated by a light source such as a laser beam to scan the resultingbeam of light across an imaging element such as an electrophotographicdrum in a laser printer. If operated at, or near, its resonantfrequency, the MEMS device is a resonant galvanometric (galvo) device.

The resonant galvo device includes a central mirrored plate suspended bytwo extensions of the plate material. The plate material extensions areintegral with a surrounding frame. Preferably the mirrored plate,extensions, and frame are cut or etched from a single silicon wafer. Acoil of conductive wire or permanent magnets are placed on the plate toprovide a first magnetic field, and a reflective surface is formed onthe plate to create a mirror.

The entire resonant galvo device is located within a second magneticfield that opposes the first magnetic field provided by the coil ormagnets on the plate. Like the first magnetic field, the second magneticfield may be provided by a coil or wire or permanent magnetic. At leastone of the first or second magnetic fields is provided by currentpassing through a coil of wires to provide a variable magnetic field.The variable magnetic field exerts a force on the magnets which causesrotation or twisting of the plate about its extensions (torsion bars).The spring rate of the extensions and the mass of the plate provide arotational spring-mass system with a specific resonant frequency. Thegalvo device functions as a laser scanner when a laser beam is directedat the oscillating surface of the mirrored plate.

In a preferred embodiment, the invention provides an improved opticalscanning system. The optical scanning system includes a resonantoscillating device having a first magnetic field and a mirrored surface.Also included in the system is a first light source for directing afirst beam of light to the mirrored surface of the resonant oscillatingdevice to provide a first reflected scan beam. A second light source isprovided for directing a second beam of light to the mirrored surface ofthe resonant oscillating device to provide a second reflected scan beam.The second reflected scan beam is offset a first distance from the firstreflected scan beam. A second magnetic field in the system interactswith the first magnetic field to provide torque to the resonantoscillating device for scanning the first and second reflected scanbeams across a surface to provide first and second scan lines on thesurface substantially simultaneously as the resonant oscillating deviceoscillates under the influence of the first and second magnetic fields.The first and second scan lines are spaced apart from one another by asecond distance.

The concept of a “light source” is broad. For example, a first andsecond light source may be implemented by providing two separate lasersthat are directly modulated or a laser and a beam splitter with externalmodulation. The laser and the beam splitter produce two beams of lightand therefore the combination constitutes both a first light source anda second light source in this case.

The invention is not limited to two light beams. For example, a VCSEL(Vertical Cavity Surface Emitting Laser), by its fabrication method, iseasier to make into an array, and for example an eight laser array maybe used to produce eight light beams that may each be used in thepresent invention.

In a preferred embodiment, the invention provides a method forincreasing the throughput and efficiency of an optical scanning system.In the optical scanning system, a current is applied to a coil at adrive frequency to create an oscillating magnetic field (e.g. the firstor second magnetic field) and to cause the resonant oscillating deviceto oscillate at resonant frequency as the resonant oscillating device isilluminated by the first and second light sources thereby providing thefirst and second reflected scan beams.

An advantage of the invention is that the apparatus and method enableincreased throughput without the need for increasing the frequency ofoscillation of the resonant oscillating device. For example in a printerwhere data is encoded onto the light beams, the addition of multiplesources does not change the total scan time, nor does it change theusable print time, relative to the speed of the oscillating device.However, it does change the usable print time relative to a data clockby N, where N is the number of sources. In other words, more print datacan be transmitted in a given period of time and thus the throughput isincreased.

Also, to achieve greater scan efficiency, one embodiment of theinvention uses bi-directional scanning of light beams across a surface.Another advantage of the two beam embodiment is that increased scans perinch may be obtained for the same oscillating scan frequency as anoscillating scanner having only a single light source. This enables atwo laser printer using the system to provide double the printresolution as compared to a single laser system, assuming both systemshave the same oscillation speed. In the alternative, it enables theoscillating scan frequency to be cut in half for a two laser system andstill achieve substantially the same print speed or throughput as asingle laser system. Similarly, an eight laser system utilizing thepresent invention achieves eight times the throughput as compared to asingle laser system.

In the two beam embodiment, a single beam may be monitored to determinethe position and movement of both beams. For example, a single sensormay be disposed in the path of the first reflected scan beam and thesensor output may be used as information relating to the position ofboth beams. Thus, two beams are monitored for the price of one sensor.

BRIEF DESCRIPTION OF THE DRAWINGS

Details of exemplary embodiments of the invention will be described inconnection with the accompanying drawings, in which

FIG. 1 is a somewhat schematic plan view of a representative torsionoscillator that may be used in one embodiment of the invention;

FIG. 2 is a somewhat diagrammatic top or plan view of one torsionoscillator that may be used in embodiments of the invention;

FIG. 3 is a cross sectional view of the torsion oscillator of FIG. 2taken along line 3—3 in FIG. 2;

FIG. 4 is a somewhat diagrammatic plan view of the torsion oscillator ofFIG. 1 with a plate 52 removed to reveal coils 58;

FIG. 5 is a somewhat diagrammatical plan view of another torsionoscillator that may be used in embodiments of the invention;

FIG. 6 is a cross sectional view of the torsion oscillator of FIG. 5taken along section line 6—6 in FIG. 5;

FIG. 7 is a view of the torsion oscillator of FIG. 6 with a plate 52removed to reveal magnets 66;

FIG. 8 is a graph illustrating a typical oscillator resonant frequencyresponse at varying temperatures;

FIG. 9 is a schematic illustration of a laser scanning and detectionsystem of one embodiment of the invention;

FIG. 10 is a schematic illustration of a typical imaging devicerepresenting one embodiment of the invention;

FIG. 11 is a graph of two scan amplitude responses created by a torsionoscillator reflecting a light beam;

FIG. 12 is a graph of a laser scan with sensors disposed adjacent eitherside of an imaging window;

FIG. 13 is a schematic diagram of an imaging system illustrating analternate embodiment of this invention;

FIG. 14 is a schematic diagram of another imaging system representingyet another embodiment of the invention;

FIG. 15 is a graph that illustrates scan angle versus time for thetorsion oscillator of FIG. 9;

FIG. 16 is a flow chart of a control sequence to implement oneembodiment of this invention;

FIG. 17 is a graph of oscillation of a torsion oscillator or a laserscan with a dynamic physical offset;

FIG. 18 is a somewhat schematic plan view of a torsion oscillator havingan oval oscillating plate;

FIG. 19 is a cross sectional view of the plate of the torsion oscillatorof FIG. 18;

FIG. 20 is a cross sectional view of the torsion oscillator of FIG. 18;

FIG. 21 is a somewhat schematic plan view of a torsion oscillatorshowing alternative reflective surfaces;

FIG. 21 a is a view of the back surface of an oscillating plate;

FIG. 21 b is a view of the front surface of an oscillating plate;

FIG. 22 is a graph of oscillation of a torsion oscillator or a laserscan at two amplitudes and one frequency;

FIG. 23 is a diagram illustrating the interaction of a scanning laserand a sensor in accordance with an embodiment of the present invention;

FIG. 24 is a diagram illustrating the relationship between the drivesignal and feedback sensor signal of a device constructed in accordancewith an embodiment of the present invention;

FIG. 25 is a diagram illustrating the interaction of a scanning laserand a sensor in accordance with an embodiment of the present inventionthat utilizes a reflecting mirror;

FIG. 26 is a diagram further illustrating the interaction of a scanninglaser and a sensor in accordance with an embodiment of the presentinvention that utilizes a reflecting mirror;

FIG. 27 is a block diagram of the components used to implement apreferred embodiment of the present invention;

FIG. 28 is a graph that illustrates scan angle versus time for a torsionoscillator used in a bi-directional scanning system;

FIG. 29 schematically illustrates the forward and reverse scan paths ofa scanning light beam;

FIG. 30 illustrates a sensor feedback signal generated by sensors placedwithin the scanning path of the light beam of FIG. 29;

FIG. 31 is a block diagram of a control system for a bi-directionalscanning system;

FIG. 32 is a schematic drawing of a preferred RIP buffer;

FIG. 33 is a graphic representation of four frequency responses of thescan amplitude of an oscillating scanner operating at four differenttemperatures;

FIG. 34 is a graphic representation of variations in the scan amplitudeof an oscillating scanner with respect to changes in the drive frequencythat illustrates an effective bandwidth of an oscillating scanner;

FIG. 35 is a graphic representation of the phase shifts in oscillationthat occur around the resonant frequency of an oscillating scanner;

FIG. 36 is a block diagram of a device constructed in accordance with anembodiment of the present invention;

FIG. 37 is a flow chart of a preferred method in accordance with thepresent invention;

FIG. 38 is a schematic diagram of a printing apparatus using a dual beamlight source;

FIG. 39 illustrates trace patterns produced by a dual beam scanner and asingle beam scanner;

FIG. 40 illustrates trace patterns produced by a dual beam scanner and asingle beam scanner operating in a bi-directional mode;

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Preferred embodiments of the present invention utilize a torsionoscillator. The torsion oscillator 50 of FIG. 1 comprises a centralrectangular plate 52 suspended by two extensions 54 a, 54 b of thematerial of plate 52. Extensions 54 a, 54 b are integral with asurrounding frame 56. Typically, the plate 52, extensions 54 a, 54 b andframe 56 are cut or etched from single silicon wafer. A coil 58 ofconductive wire and a mirror 60 or similar reflective surface are placedon the central plate. The mirror may be a smooth or polished surface onthe silicon plate 52, since silicon itself is about sixty percentreflective.

This entire assembly is located inside a magnetic field 62 (shownillustratively by lines with arrows), such as from opposing permanentmagnets (not shown in FIG. 1). When a current passes through coil 58, aforce is exerted on coil 58 that is translated to plate 52 since coil 58is attached to plate 52. This force causes rotation of plate 52 aroundextensions 54 a, 54 b that twist with reverse inherent torsion.

With reference to FIGS. 2–4, another embodiment of a torsion oscillator64 is shown. In this embodiment, at least one magnet 66 is placed on theplate 52. At least one coil 58 is placed on the frame 56 in acorresponding position below or around plate 52. FIG. 3 depicts thepositioning of magnet(s) 66 and coil(s) 58 in a cross sectional view ofthe torsion oscillator 64 taken along line 3—3 in FIG. 2. FIG. 4 showsthe plate 52 removed and extensions 54 a and 64 b broken away to revealthe coil(s) 58 adjacent the frame 56.

As described in more detail hereafter, an alternating electrical drivesignal, such as a square wave or a sine wave, is applied to the coil(s)58 to produce an alternating electromagnetic field that interacts withthe magnetic field of the magnets 66 and oscillates plate 52.

Another torsion oscillator 70 that may be utilized in another embodimentof the invention is shown in FIGS. 5–7. FIG. 5 is a somewhatdiagrammatic plan view that shows at least one coil 58 placed directlyon the plate 52. FIG. 6 shows the placement of at least one magnet 66 onframe 56 in a position corresponding to the placement of the coil(s) 58on plate 52. FIG. 6 is a cross sectional view of the oscillator 70 takenalong line 72—72 in FIG. 5. FIG. 7 is a plan view of the torsionoscillator 70 with plate 52 removed and extension 54 a and 54 b removedsuch that FIG. 7 depicts the placement of magnet(s) 66 adjacent theframe 56. As described above, the magnetic field of magnet(s) 66 and thealternating current in coil(s) 58 create a force that causes rotationaloscillation of the plate 52 about extensions 54 a, 54 b with reverseinherent torsion. The alternating current in coils 58 will be producedby an electrical drive signal applied to the coils 58 at an electricaldrive frequency. Typically, the torsion oscillator 70 will oscillate ata mechanical operating frequency that is the same as, or substantiallythe same as, the electrical drive frequency. There may be a phase shiftbetween the mechanical operating frequency and the electrical drive offrequency that may produce a small difference in frequency, at least fora short period of time. Also, the mechanical operating frequency may bea harmonic of the electrical drive frequency in some applications, butpreferably the mechanical operating frequency and the electrical drivefrequency are the same.

Other means may be employed to make such a system oscillate, such asstatic electricity, piezoelectric forces, thermal forces, fluid forcesor other external magnet fields or mechanical forces. The use of coildrive by electric current in the various embodiments should beconsidered illustrative and not limiting.

The oscillator 50 functions as a laser scanner when a light beam isdirected at the oscillating surface of mirror 60 instead of the muchbulkier rotating polygonal mirror widely used in laser printers andcopiers. Torsion oscillators also have other applications in whichmirror 60 would not necessarily be used.

The spring rate of extension 54 a, 54 b and the mass of plate 52constitute a rotational spring-mass system with a resonant frequency.Plate 52 can be excited to oscillate by an alternating current passingthrough the coil 58. To conserve power, the optimal electrical drivefrequency of the current driven through coil 58 is the currentlyexisting resonant frequency of the oscillator. However, the resonantfrequency changes with environmental conditions, particularly withdifferences in temperature and also with differences in atmosphere (e.g.a vacuum or different fluids). Accordingly, for optimal operation of atorsion oscillator scanner the optimal electrical drive frequency ofoperation is variable. As above noted, the electrical drive frequencyproduces a mechanical operating frequency that is typicallysubstantially equal to the electrical drive frequency.

The resonant frequency of a torsion oscillator is typically very sharplydefined, meaning that scan amplitude drops significantly if theelectrical drive frequency varies to either side of the currentlyexisting resonant frequency. (This is also known as a high Q system.)For example, if the electrical drive frequency is held constant, theresulting mechanical frequency is also relatively constant. As changesin environmental conditions cause the resonant frequency of the torsionoscillator to change, the performance of the torsion oscillator willchange. As aforementioned, the resonant frequency of a particular devicecan change with environmental conditions such as temperature ordifferences in atmosphere.

Typically, because of thermal expansion of material in the oscillator,resonant frequency of a silicon torsion oscillator drops with increasingtemperature. FIG. 8 is a plot of such a typical system response withelectrical drive frequency as the horizontal axis and amplitude ofoscillation as the vertical axis, at a constant drive level for eachtemperature shown in FIG. 8. As used herein, a constant drive levelpreferably refers to a constant drive voltage or a constant drivecurrent. However, in non-preferred applications it may also include aconstant drive power. The left, dashed graph shows the response of thesystem at a temperature T1, which is the highest temperatureillustrated. The solid graph shows response of the system at atemperature T2, which is lower than T1 but higher than T3, T2 beingroughly centered in temperature between T1 and T3. The right, dashedgraph shows the response of the system at temperature T3, the lowest ofthe three temperatures.

When the resonant frequency of the oscillator 50 changes, the controllogic as hereinafter described may change the electrical drive frequencywhich changes the mechanical operating frequency of the oscillator 50,thereby maintaining the same physical oscillation amplitude.Alternatively, the control logic may change the drive level of theelectrical drive signal while maintaining the same electrical drivefrequency to thereby maintain the same physical oscillation amplitude ofthe oscillator 50, or the control logic may do nothing to the electricaldrive signal and allow the physical oscillation amplitude of theoscillator 50 to change. If the control logic changes the electricaldrive frequency, that changes the amplitude of the physical oscillation,the rate at which a laser is scanned across a target will change.

For example, assume the resonant frequency of the oscillator 50increases, but the drive level and frequency of the electrical drivesignal remain the same. Also assume that the absolute difference betweenthe electrical drive frequency and the resonant frequency increases. Insuch a case, the physical amplitude of the oscillation will decreasebecause the oscillator 50 is physically harder to drive. When theoscillator 50 is used in a laser scanning apparatus 74 as discussedhereinafter with reference to FIGS. 9 and 10, a decrease in theoscillation amplitude of oscillator 50 will cause a decrease in the scanamplitude of the laser. By scan amplitude it is meant the movement ofthe light beam as it sweeps from the farthest point on one side to thefarthest point on the other side of the laser's sweep or scan asillustrated by arrow 76 in FIG. 9. The imaging window is that part ofthe scan amplitude in which data can be directed to a surface beingimaged with light modulations. Typically, the imaging window is at ornear the middle of the light beam sweep.

The imaging window must be within all allowed scan amplitudes of thelaser. For example, consider FIG. 11 which graphically represents twoscan amplitudes. The X axis represents time and at the Y axis representsamplitude of a laser scan. Curve 120 represents a large amplitude laserscan and curve 122 represents a small amplitude laser scan. Both curves120 and 122 are grossly exaggerated, and one would not necessarilyexpect either of these two scans to be found in a typical scanningapparatus. However, the exaggeration helps illustrate the relationshipbetween the scan amplitude and the speed of the light beam as it crossesthe imaging window. In this illustration, the imaging window isrepresented by dashed lines 124 and 126. The time, t1, represents thetime required for curve 122 to cross the imaging window from the dashedline 124 to the dashed line 126. Likewise, the time, t2, represents thetime required for curve 120 to cross the imaging window from the dashedline 124 to the dashed line 126. Clearly, t2 is much smaller than t1,which means that the laser scan represented by curve 120 is travelingmuch faster across the imaging window than the laser scan represented bythe curve 122. If both laser scans are to be used to optically place thesame data onto a target, the data rate associated with curve 120 must befaster than the data rate associated with curve 122. For example, if alaser printer is designed to print a fixed number of dots across animaging window, it must print the dots at a faster rate if the laserscan corresponds to curve 120, as compared to a laser scan correspondingto curve 122. Thus, while the electrical drive frequency of a laserscanner is important, it does not necessarily dictate the actual timerequired for a light beam to cross the imaging window.

Two Sensor Laser Scanner

One way to determine the time required for a light beam to scan acrossan imaging window is to use a pair of sensors disposed adjacent oppositesides of the imaging window at a fixed distance from the imaging window.FIG. 12 is a graph illustrating a laser scan with a pair of sensorsdisposed adjacent either side of an imaging window. In FIG. 12, curve128 represents the laser scan with the X axis representing time and theY axis representing amplitude. Dashed line 130 represents the positionof one optical sensor relative to the laser scan represented by curve128 and, likewise, dashed line 132 represents the position of the othersensor. Dashed lines 134 and 136 represent the opposite sides of theimaging window, and the distance between lines 134 and 136 representsthe amplitude or size of the imaging window. The sensors represented bylines 130 and 132 are positioned adjacent to, and on opposite sides of,the imaging window represented by lines 134 and 136. As the light beamsweeps across the sensors at lines 130 and 132, each sensor generates asignal and the time difference between the two sensor signals is thetime required for the light beam to sweep from one sensor to the other.In FIG. 12, lines 138 and 140 indicate the time at which the laser scanof curve 128 swept across the sensors indicated by lines 130 and 132.The arrow 142 indicates the time required for the light beam to scanfrom one sensor to the other, which is referenced as “t-sensor” in FIG.12. Lines 144 and 146 indicate the times at which the laser scan ofcurve 128 crosses the edges of the imaging window defined by lines 134and 136. The arrow 148 represents the time for the light beam to scanacross the imaging window of lines 134 and 136, which is referenced as“t-image” in FIG. 12.

The distance between the sensors represented by lines 130 and 132 andthe edges of the imaging window represented by lines 134 and 136 isknown and is preferably small. Thus, the time difference betweent-sensor and t-image may be calculated or approximated. Likewise, thetime delay between the light beam striking the sensor and the light beamcrossing an edge of the imaging window may be calculated orapproximated. In one embodiment, the sensors represented by lines 130and 132 are placed very near the imaging window represented by lines 134and 136. Thus, the difference between t-sensor and t-image is smallrelative to the size of t-image. The distance between lines 138 and 144represents the time delay required for the light beam to travel from thesensor represented by line 132 to the leading edge of the imaging windowrepresented by line 136. The distance between line 146 and line 140represents the time delay required for the light beam to travel from thetrailing edge of the imaging window represented by line 134 to thesensor represented by line 130. If the sensors are placed very near theimaging window, these time delays are small relative to t-image and maybe approximated by a constant or by a constant percentage of t-sensor.Alternatively, a lookup table may be provided that gives the time delaysassociated with each value of t-sensor, which will provide a veryprecise value for the time delays.

Using t-image and the time delays, the timing and the frequency of thedata to be encoded in the laser is determined. The frequency isdetermined by dividing the total number of bits of data (pel slices) byt-image. When the laser passes the sensor represented by line 132 and ismoving toward the sensor represented by line 130, the system waits for atime delay as discussed above, and then begins encoding or modulatingthe laser with the data. By reference to FIG. 12, it is noted that eachsensor represented by lines 130 and 132 will produce two consecutivepulses. The leading edge of the imaging window is signaled by the secondpulse from the sensor of line 132, one of which occurs at theintersection of curve 128 and line 138, for example. The timing of thedata is preferably based upon that second pulse.

If the oscillator 50 is functioning as a laser scanner, as the resonantfrequency changes at a constant electrical drive level and unchangedelectrical drive frequency, scan amplitude varies, which varies the timeof beam sweep between two sensors adjacent opposite sides of an imagingwindow. The imaging window is that part of the sweep in which data canbe directed to a surface being imaged in the form of light modulation(such as on and off of the light beam at predetermined time periods). Inone application the imaging window is centered generally in the middleof the beam sweep and is typically, about 8.5 inches in width, but theimaging window could be off-center relative to the beam sweep, butwithin the beam sweep. Likewise, the imaging window could be greater orsmaller than 8.5 inches depending upon the particular application.

Apparatus to control the operation of this invention may includeelectronic control, such as a microprocessor or combinational logic inthe form of an Application Specific Integrated Circuit (commonly termedan ASIC).

To illustrate the two-sensor implementation, a representative, schematicdiagram of a laser scanning and detection system 74 is shown in FIG. 9.An oscillator 50 may be that of FIG. 1 although other embodiments of anoscillator may be employed including those shown in FIGS. 2–4 and 16–18.A light source such as for example laser 78 trains a light beam 80 ontothe mirror 60 (see FIG. 1). As shown in FIG. 9, the scan amplitude isshown by broken lines 82 a and 82 b indicating the outer limits of thereflected laser scan (the scan amplitude) and arrow 76 indicating thelargest angle of scan. The reflected light beam 84 is shown at a zeroangle of scan and coincident with a middle line 86 in FIG. 9.

The outer limits of the scan amplitude (82 a and 82 b in FIG. 9) are notsensed in this embodiment and need not be sensed to implement preferredembodiments of this invention. Two sensors, A and B, are located withinthe outer limits 82 a and 82 b separated from the middle (line 86) byknown angles a and b. The total angle between the sensors A and B isdetermined by adding angles a and b. Upon receiving the reflected lightbeam 84, sensor A creates an electrical signal online 88 to controllogic 90, which may be a microprocessor. Sensor B, upon receiving thereflected light beam 84, also creates an electrical signal on line 92 tocontrol logic 90, which may be any type of logic system and may be basedon microprocessors, ASICs, programmable logic, or other electronicdevices.

When the system of FIG. 9 is used in a scanning apparatus, such as aprinter, it typically includes optics, such as mirrors or lenses, butsuch optics are not shown in FIG. 9 for purposes of clarity ofillustration. Examples of optic configurations are shown in FIGS. 13 and14. FIG. 13 depicts an optic configuration having a lens 150 that isused to direct the reflected light beam 152 as it oscillates betweenpositions indicated by beams 152 a and 152 b. FIG. 14 shows an opticconfiguration of mirrors 200 used to reflect the reflected light beam152. The path of reflected light beam 152 is shown by dashed lines 202 aand 202 b. The optic configurations in FIGS. 13 and 14 are illustrativeand should not be considered limiting. Numerous other opticconfigurations utilizing lens, mirrors, or both are possible.

The sensors A and B may be positioned before or after or inside theoptics. (Again, “or” inclusively means one or more or all of thechoices). For example, FIG. 13 shows various placements of sensors A andB. Sensors A1 and B1 are placed before lens 150 while sensors A2 and B2are placed after the lens 150. Only sensors A1 and B1 may be used or A2and B2 may be used. Alternatively, all six sensors A, B, A1, A2, B1, andB2 may be used together, or they may be used in various combinationssuch as any “A” sensor in combination with any “B” sensor, such as (Aand B2) or (A1 and B). It should also be appreciated that sensors A, B,A1, B1, A2, B2, or combinations thereof may comprise a reflectivesurface such as a mirror. In such an embodiment, a sensor comprising amirror would reflect the light beam 152 to another sensor. For example,in FIG. 13 sensor B2 could comprise a mirror that would reflect thelight beam 152 to sensor A2. FIG. 14 shows placement of sensors A3 andB3 after mirrors 200. Sensors A3 or B3 could also comprise a reflectivesurface(s) reflecting light to other sensors.

The mechanical operating frequency of the laser scan may be detectedusing sensors A or B using a variety of techniques. For example, bymeasuring the time between a single signal from one sensor A or B (suchas sensor A) followed by two, separated signals from the other sensor,(such as sensor B), and then the next two signals from sensor A, theelectric drive frequency may be detected. FIG. 15 is illustrative, withvertical lines on the upper, vertical scale indicated as - - a - - beingthe time of signals from sensor A and the vertical lines on the lower,vertical scale indicated as - - b - - being the time of signals from thesensor B. The sinusoidal wave shown is illustrative of the laser's scanamplitude as a function of time as it scans between lines 82 a and 82 b.

The time t0, between two consecutive signals from sensor A is the periodwhen the light beam sweeps from sensor A, reaches its widest point(illustrated as line 82 a in FIG. 9) and returns to sensor A. The timet1 is the period when the beam sweeps from sensor A to sensor B, therebytraversing the imaging window discussed in the foregoing, which isgenerally centered on the middle of the sweep (illustrated as line 86 inFIG. 9) and is between sensors A and B. The time t2, between twoconsecutive b signals is the period when the beam sweeps from sensor B,reaches its widest point (illustrated as line 82 b in FIG. 9) andreturns to sensor B. The time t3 corresponds to the time t1 while thebeam is moving in the opposite direction.

Accordingly, observation of a sequence of signals unique to one fullcycle, such as a, b, b, a, a or b, a, a, b, b defines the period, whichis the reciprocal of scan frequency. FIG. 15 depicts observation of asequence of signals a, a, b, b, a, a b, b. Within the observation shownin FIG. 15, a cycle is defined by the following sequences 1) a, a, b, b,a; 2) a, b, b, a, a; 3) b, b, a, a, b; and 4) b, a, a, b, b.

The cycle information and particularly t-image is used to adjustparameters in an imaging system 94 such as the system schematicallyshown in FIG. 10. Referring again to FIG. 12, upon control logic 90observing t-sensor of the light beam sweep, control logic 90 calculatest-image and implements an adjustment as required to conform to t-image.A photoconductor, illustrated as drum 96 in FIGS. 10 and 13, rotated bydrive train 98 receives light from the reflected light beam 152 througha lens 150 when the reflected light beam 152 is within the imagingwindow during its sweep as described above. The outer boundaries of theimaging window are illustrated by broken lines 100 a and 100 b. Drivetrain 98 is controlled by control logic 90 along path 102 to adjust therate of rotation of drum 96. Similarly, control logic 90 sends driveinformation to the laser 104 along path 106 to modulate the laser 104.

Alternative imaging systems 154 and 156 are schematically shown in FIGS.13 and 14. It should be noted that in FIGS. 13 and 14 path 158 betweencontrol logic 90 and torsion oscillator 50 is simplified for clarity ofillustration. Path 158 may include elements such as a frequencygenerator, an amplitude adjustment system, an offset adjustment system,or a power drive system. Such elements are discussed in more detail withreference to FIG. 9.

In FIG. 13, paths 160 and 162 connect sensors A1 and B1 respectively tocontrol logic 90. Sensor A2 sends a light detect signal along path 164to control logic 90 while sensor B2 utilizes path 166 to transmit asignal to control logic 90. In FIG. 14, sensors A3 and B3 are connectedto control logic 90 by paths 168 and 170 respectively.

Laser 104 is typically modulated to produce dots on a media, and thedots are often called pels. In printing applications, for example, eachpel is often divided into a number of pels slices, for example 12 pelslices. To print a full pel, usually, only a number of pel slices areactually printed. For example, the laser 104 would typically bemodulated to illuminate eight of the 12 pel slices to create a singleprinted pel. Thus, the modulation rate of laser 104 is determined inpart by the pel density, in part by the number of pel slices, and inpart by the speed of the light beam 152 as it sweeps across the imagewindow defined by lines 100 a and 100 b.

In accordance with a preferred embodiment of this invention, therotation speed of the photoconductor drum 96 is adjusted on drive train98 by control logic 90 to provide a constant, desired resolution inprocess direction (the process direction being the directionperpendicular to the sweep direction). Similarly, the modulation periodof laser 104 is adjusted by control logic 90 to provide a constant,desired resolution in the beam sweep direction.

Drum 96 is chosen illustratively as a photoconductor drum. The imageadjacent such a drum is a latent electrostatic image resulting fromdischarge of the charged surface of the drum by light. Such an image issubsequently toned with toner particulates to be visible, transferred topaper or other media, and then fixed adjacent the media, as by heat orpressure. It will be understood that other surfaces being imaged maytake adjacent the final image directly by reaction to light, such asphotosensitive paper, or may take adjacent a non-electrostatic latentimage that will later be developed in some manner.

Laser Beam Modulation

Referring to FIG. 12, the modulation of laser beam 104 may beunderstood. As shown in FIG. 12, the time required for the reflectedlight beam 152 to sweep across the computed imaging window (148,t-image) is a fraction of the measured time required for the reflectedlight beam 152 to sweep across sensors A and B (142, t-sensor). Thatfraction depends on several factors, including the optical design of theimaging system. A preferred embodiment of this invention determines thetime interval necessary for the data rate calculation from a theoreticalmodel of the imaging system design and from a calibration constant setat the time that the system is manufactured. In the preferredembodiment, the ratio of imaging window (t-image) to the period of timebetween sensors A and B (138 to 140) (t-sensor) may be deemed constantas the scan amplitude varies since the variance is not significant. Thisratio may be, for example, 0.95 (i.e., 95 percent of the time (t-sensor)of the sweep between sensors A and B is the imaging window, t-image).This ratio is referred to as the window ratio.

The formula for the time period to drive each pel slice (or the timebetween the leading edges of each drive pulse), which is implemented bycontrol logic 90 is the following: [(Scan Time Between Sensors A andB(t-sensor)) times (Window Ratio)] divided by [(quantity (eg., PrintWidth)) times (resolution) times (pel slices per pel). Stateddifferently, the data encoding frequency for laser 104 will be theproduct of the image scan width times the resolution times the number ofpel slices per pel divided by t-image.

Assuming a scan time between the sensors of 100 microseconds, a windowratio of 0.95, a print width of 8.5 inches and resolution of 600 dpi andonly one pel slice per pel, the scan time for each pel is(100×0.95)/(8.5×600×1)=18.6 nano seconds.

The formula for the rate of travel of the receiving surface, such astangential velocity of the photoconductor drum 96, which is alsoimplemented by the control logic 90, is the following: (Inches TraveledPer Cycle) divided by (Time Per Each Scan Cycle).

The time per cycle is the period of the oscillator. The inches-per-cycleis the intended resolution in the process direction. Assuming anoscillator 50 mechanical operating frequency of 2000 Hz, the period (orcycle) is the reciprocal, ( 1/2000) or 500 microseconds. Assuming aresolution in the process direction of 600 dpi, the inches per cycle is1/600 inch, and the rate of travel in the process direction is (1/600)/500=3.333 inches per second.

Control Sequence and Adjustment Events

FIG. 16 is a simplified flow chart illustrating a high level conceptualview of a scanning and adjustment process illustrating a sequence ofcontrol for embodiments of the invention. It will be understood thatother detailed operations, such as error checking and interruptions,have been omitted for the sake of clarity. The first action is power on(Turn On), action 206. Control logic 90 then proceeds to action 208 inwhich the currently existing resonant frequency of the oscillator isdetermined by driving the oscillator 50 at a constant drive level,varying the frequency of the drive signal and monitoring the oscillationamplitude of oscillator 50. Alternatively, the oscillator may be drivenat a constant frequency as discussed in more detail below. The frequencythat produces the largest oscillation amplitude is the currentlyexisting resonant frequency. Amplitude of oscillation may be determinedin a number of ways, as discussed herein.

Referring to FIG. 16, after directly or indirectly observing ordetermining the currently existing resonant frequency, control logic 90sets the electrical drive level at a predetermined level and sets theelectrical drive frequency for oscillator 50 at or near the currentlyexisting resonant frequency, and then moves to action 210. The timerequired for the laser to scan the imaging window is then sensed anddetermined as previously described with respect to t-image. Usingt-image, control logic 90 then determines and sets the speed of thescanned medium as indicated in action 212 or determines and sets thefrequency for encoding of the laser with data as indicated at action214. Depending upon the application, one or both of actions 212 and 214may be performed. Ideally, actions 212 and 214 are performedsimultaneously when both actions are needed, or almost simultaneously ina very rapid consecutive order.

After actions 212 or 214 are performed, control logic 90 moves to action216 and determines whether a speed adjustment event has occurred. Aspeed adjustment event is determined based on the application. Forexample, in a printing application, the speed adjustment event may be atime delay from the previous speed adjustment. In other words, the speedadjustment event is simply time, and speed is adjusted periodicallybased on time. A speed adjustment event could also be an outside eventsuch as a pause in printing or a media change, for example a paperchange. If a speed adjustment event has occurred, control logic 90returns to action 210 and repeats the process of adjusting speed aspreviously discussed. If a speed adjustment event has not occurred, theprocess moves to action 218.

Again, depending upon the application, it may be desirable to adjust theelectrical drive frequency during operation. In other applications, thiswill not be necessary. If the optional electrical drive frequencyadjustment is implemented for a particular application, at action 218the control logic 90 will determine whether a drive frequency adjustmentevent has occurred. Again, a drive frequency adjustment event may be themere passage of time since the last adjustment, an internal event suchas a change in the laser scan amplitude or speed, or it may be anoutside event such as a media change, for example a paper change. In thepreferred embodiment, speed adjustment is performed on the fly withoutinterfering with the scanning or printing process. Likewise, drivefrequency and amplitude adjustment are preferably performed on the fly.However, in other embodiments, operations such as printing may bestopped to perform these adjustments if necessary.

If a drive frequency adjustment event has not occurred, the process willmove to action 220 and will determine whether an event has occurredrequiring adjustment of the drive amplitude. If such event has occurred,the process moves to action 222 and the amplitude is adjusted as needed.Typically, the drive amplitude will be adjusted when the clocked times,(such as t0, t1, t2 and t3) indicate that the scan amplitude is toosmall or too large, and the magnitude of the adjustment will typicallybe dependant on the clocked times. If a drive amplitude adjustment eventhas not occurred, the process will loop back to action 216 and willcontinue to loop through actions 216, 218 and 220 until either a speedadjustment, a drive frequency adjustment, or, a drive amplitudeadjustment is required. If a drive frequency adjustment event hasoccurred, the process will move to action 208, determine the currentlyexisting resonant frequency and set the electrical drive frequency andamplitude in the manner previously discussed.

Adjustment of the drive signal may be accomplished as follows, withreference to FIG. 9. The frequency, amplitude and offset control of FIG.9 may operate in parallel with other operational logic or as anindependent logic loop. As discussed in the foregoing, control logic 90determines information corresponding to the currently existing resonantfrequency (or the reciprocal thereof). To adjust the electrical drivefrequency to correspond to the currently existing resonant frequency,control logic 90 creates a frequency control signal indicating a newelectrical drive frequency on line 108. The new electrical drivefrequency is preferably near the currently existing resonant frequency,but shifted a known shift frequency in a known direction relative to thecurrently existing resonant frequency. The new electrical drivefrequency may also be set at precisely the currently existing resonantfrequency in alternate embodiments. Line 108 connects to a frequencygenerator 110, which creates a signal having the new electrical drivefrequency on line 112. The signal on line 112 is connected to amplitudeadjust system 114. Control logic 90 also creates an amplitude controlsignal that defines a required amplitude on line 116. Line 116 connectsto amplitude adjust system 114, which creates a signal having the newelectrical drive frequency and the required amplitude on line 118. Thesignal on line 118 is connected to a drive amplitude offset adjustsystem 172. As discussed below in more detail, because of the dynamicphysical offset of the torsion oscillator 50, there is a departure fromthe sweep being centered about the center position indicated by line 86in FIG. 9. Control logic 90 preferably uses the difference between theintervals t0 and t2 illustrated in FIG. 15 to determine the dynamicphysical offset, and based on that, produces a control signal on line174 defining a required drive amplitude offset that will compensate forthe dynamic physical offset. The signal on line 174 is connected tooffset adjust system 172.

The output of the offset adjust system 172 is a signal having the newelectrical drive frequency, the required amplitude, and the driveamplitude offset on line 176. Line 176 is connected to power drivesystem 178, which creates an analog signal corresponding to thisinformation on line 180, which is the new electrical drive signal thatdrives oscillator 50. Although shown as separate elements, it should beappreciated that many of the elements of FIG. 9 could be incorporatedinto a single device such as an ASIC.

In considering the process described above, it should be noted that thedrive level adjustment is the easiest and most practical adjustment toimplement, and it is preferred to design the oscillator 50 and definethe adjustment events so that the drive level is the first to beadjusted, and adjustment of the drive frequency and speed are rarely ornever required. In a stable application, the oscillator 50 may bedesigned so that the drive frequency and speed are set at a constantduring manufacturing, and only the drive level is adjusted duringoperation.

Dynamic Physical Offset

Referring now to FIG. 17, there is shown a sinusoidal curve 230representing the oscillation of oscillator 50 with a dynamic physicaloffset that was discussed above. In FIG. 17, line 232 represents thephysical center position at which the oscillator 50 will reflect thelight beam 80 to a center position (line 86) in the imaging window asshown in FIG. 9. If there is no static offset, the physical centerposition is the rest position of the oscillator 50. Ideally, theoscillator 50 would oscillate about a physical center position definedby line 232. However, due to imbalances and structural variances,dynamic phenomena depending upon differences between the device resonantfrequency and applied electrical driving frequency, or disturbances tothe system such as mechanical shock, vibration or airflow, theoscillator 50 will oscillate about a center position that does notcorrespond to physical centerline 232. Instead, when driven by abalanced electrical drive signal, it will oscillate about a centerposition such as that represented by dashed centerline 234. A balancedelectrical drive signal is one that does not favor either direction ofoscillation and does not compensate for the dynamic physical offset ofthe oscillator 50. The distance between lines 232 and 234 represents anangular distance between the ideal physical centerline 232, the restposition of the oscillator 50, and the actual dynamic centerline whichrepresents the position of the oscillator 50 when it is positionedexactly halfway between the maximum angular position of the oscillator50 in both positive and negative directions during physical operation.This angular distance represented by the distance between lines 232 and234 is also called “dynamic physical offset”. In FIG. 17, the dynamicphysical offset has been grossly exaggerated for purposes ofillustration. With continuing reference to FIG. 17, dashed line 236represents the position of sensor A while dashed line 238 represents theposition of sensor B. Sensor A produces pulses in response to thereflected light beam 84 when curve 230 crosses dashed line 236, andsensor B produces pulses when curve 230 crosses dashed line 238. Thetime delay between two pulses created by sensor A is represented by toand the time delay between two pulses created by sensor B is representedby t2. Under ideal conditions, t0 would equal t2. However, because ofthe offset between the physical centerline 232 and the dynamiccenterline 234, t2 is greater than t0. Thus, in the one embodiment, thecontrol logic 90 determines offset by comparing t2 and t0. Preferably,during calibration a table or formula is provided to specify the exactamount of offset corresponding to the size differences between t2 andt0.

To compensate for the physical offset of the oscillator 50 that isrepresented in FIG. 17, the drive signal is offset in the oppositedirection. That is, if the oscillator 50 has physical characteristicscausing it to naturally oscillate further to the left (the negativedirection) then the electrical drive signal will be offset so that itdrives the oscillator harder to the right (the positive direction). Byoffsetting the drive signal in a direction opposite from the physicaloffset of the oscillator, the oscillator 50 is forced to oscillate on ornear the physical center line 232, which means the oscillator 50 has acenter scan position as indicated by reflected light beam 84 and line 86in FIG. 9. That is, in the preferred embodiment, reflected light beam 84is positioned halfway between the outermost scan positions of the laser78, is positioned in the center of the imaging window, and is positionedhalfway between sensors A and B. It will be appreciated that adjustingfor the dynamic offset is not absolutely necessary. Even with offset,the reflected light beam 84 can fully scan the imaging window and ascanning function, such as printing, is performed so long as the dataencoding rate and the speed of the print medium, such as a drum, areproperly adjusted based on the scan time across the image, t-image. Thedynamic physical offset of oscillator 50 should be limited in sizedepending upon the application and the capacity of the electrical drivesystem, such as the system represented in FIG. 9 by components 110 114,172 and 178. In essence, the dynamic physical offset should not preventthe reflected light beam 84 from illuminating both sensors A and B.

Stationary Coil

Referring again to FIGS. 2–4, one may appreciate the advantages of atorsion oscillator 64 having a central plate 52 suspended by twoextensions 54 a, 54 b. In this embodiment, the extensions 54 a, 54 boperate as a torsion spring mount and are preferably integrally formedwith a surrounding frame 56. A reflective surface, such as a mirror orthe like, is preferably included as part of the plate 52 for reflectinglight or other energy to a target. As best shown in FIG. 4, for thisembodiment of the imaging system, the coil(s) 58 are located in aneighboring configuration with respect to the plate 52, preferably onthe frame 56.

A number of advantages result from using the torsion oscillator 64 in animaging system, such as a laser printer or optical scanner. For example,by locating the coil(s) 58 away from the plate 52, it is possible toinduce a greater oscillatory range of motion in the plate 52 withoutsignificant temperature increases that affect the oscillator's resonantfrequency that may occur when the coil(s) 58 are located on the plate52. By locating the coil(s) 58 away from the plate 52, larger conductorscan be used in the coil(s) 58, since temperature influences tend to beminimal when the coil(s) 58 are located away from the plate 52. Greaterdrive currents are obtainable by using larger conductors to drive thecoil(s) 58, to thereby induce a larger oscillatory range of motion.According to a preferred embodiment of the imaging system 94, 154 or156, it is preferred to drive the coil(s) with a drive current ofbetween about fifty milliamperes and two hundred milliamperes achievingpower levels of between about two hundred fifty and one thousandmilliwatts.

According to this embodiment, the oscillating plate 52 includes at leastone magnet 66, and the frame 56 includes at least one coil 58 positionedbelow the at least one magnet 66 located on the plate. FIG. 3 depictsthe positioning of magnet(s) 66 and coil(s) 58 in a cross sectional viewof the torsion oscillator 64 taken along line 3—3 in FIG. 2. As shown inFIG. 2, line 3—3 also depicts an axis of rotation for the plate 52.

FIG. 4 depicts the coil(s) 58 on the frame 56 with the plate 52 removed.The electromagnetic field induced by magnet(s) 66 and coil(s) 58interact to cause plate 52 to oscillate around extensions 54 a, 54 b,about the plate's rotational axis (line 3—3). The plate 52 rotatesclockwise and counterclockwise about its rotational axis, whenalternating current is driven through the coil(s) 58.

For this embodiment, it is preferred to provide a sufficient power tothe coil(s) 58 to produce oscillations about the rotational axis (line3—3) of greater than about +/− fifteen degrees at a nominal frequency ofabout 2.6 kHz. The system can produce lesser amounts of oscillatorymotion; but for laser printing applications, it is most preferred toinduce rotations of greater than +/− fifteen degrees to produce qualityprinting. For a given laser printing application, a printer (such asimaging system 154 and 156) provides control signals to control thedrive level provided to the coil(s) 58 to thereby oscillate the plate 52and effect printing (scanning) operations to print an image according toimage data provided to the printer.

With reference now to FIG. 18, yet another embodiment of a torsionoscillator 240 is shown. The torsion oscillator 240 includes a centralplate 248 having a non-rectangular geometrical configuration in at leastone viewing direction. Preferably, the plate 248 has a non-rectangularshape, such as elliptical, oval, racetrack, or circular. As shown in thecross-sectional view of the plate 248 in FIG. 19, a non-rectangularshape can also be formed in a second viewing direction through thethickness of the plate 248. As shown in FIG. 20, the non-rectangularshape may be used in the third viewing direction of the plate 248 aswell. FIG. 19 depicts a cross-sectional view of the plate 248 takenalong the lines 244—244 of FIG. 18, wherein the plate 248 has asubstantially elliptical cross-section. The plate 248 can also havedifferent cross-sectional configurations, such as oval, circular, andracetrack. In one preferred embodiment, the plate 248 in plan view has asubstantially elliptical geometrical configuration, having a major axisof about four millimeters and a minor axis of about three millimeters.As described above, the plate 248 is suspended by two extensions 54 a,54 b, integral with a surrounding frame 56. A reflective surface 246,such as a mirror or the like is disposed on the plate 248 for reflectingan energy source, such as a light source, to a target.

The plate's non-rectangular shape is closer to the beam shape, reducingunused reflective area that reduces wind resistance and interferenceeffects. Additionally, the non-rectangular plate 248 tends to reduce theamount of inertia for a given plate width and helps provide higherresonant frequencies.

The non-rectangular plate 248 implementation may use a rectangular ornon-rectangular reflective surface 246 which is preferably substantiallyflat and has a shape in plan view of elliptical, circular, racetrack,oval, or the like. Reflective surface 246 is positioned on the plate 248for reflecting the light source to a target. In alternative embodiments,the reflective surface 246 can be formed as a curved, concave, and/or anetched mirror, such as an etched Fresnel lens mirror. The reflectivesurface 246 can be further subdivided into a plurality of reflectivesurfaces, having different reflective properties.

FIG. 20 depicts the positioning of magnet(s) 66 and at least one coil 58in a cross sectional view of the torsion oscillator 240 taken along line242—242 in FIG. 18. Line 242—242 also depicts an axis of rotation forthe plate 248. It should be noted that only one coil 58 may be locatedon the frame to oscillate the plate 248.

In the embodiments described above, there are other advantagesassociated with locating the coil(s) 58 away from the rotatingreflective surface 246 of the oscillator 240. For example, since thedrive coils are not located on the plate, minimal patterning exists onthe reflective surface 246. Also, power dissipation from the applieddrive current does not directly heat the oscillating plate, leading tomore consistent operation at varying drive levels. Due to the very smallarea available on the plate for coils, relatively few coil turns can beplaced on the plate, requiring a strong and bulky external permanentmagnet assembly to produce sufficient scan angles. Placing a small butpowerful magnet on the oscillating plate allows a more compact externalcoil to be used, one that can be designed to minimize intruding on theinput and output beams on the device. As compared to the coil on mirrordesign, this design essentially allows for more efficient ellipticalplate shapes without degrading the available torque to provide thedesired scan angle. Thus, this arrangement tends to provide a largerclear aperture area for the reflective surface 246 for a given surfacearea of the rotating plate 248. (With reference to the mirror, clearaperture area refers to the usable portion of the plate that can beutilized to redirect light.)

This larger clear aperture area of reflective surface 246 tends to leadto a larger scan operating window and the resultant potentialoperational speed advantages associated with a larger scan operatingwindow. These advantages are due to the fact that in devices with apatterned coil 58 on the oscillating mirror plate, some percent of theplate's surface area is covered by patterned coils. This leaves lessroom for the mirrored surface 24. Thus, the mirror area to total platearea ratio is a fraction less than one such as 50%. In the case wherethe magnets are placed on the mirror plate, the magnets can be placed onthe back surface or on the front surface along the axis of the torsionbars, above and/or below the mirror area. These options are illustratedin FIG. 21 a in which magnets 66 are mounted on the back of plate 264.In FIG. 21 b, the magnets are mounted on the front side of the plate 254aligned with the longitudinal axis of extensions 54 a and 54 b. Thisresults in a mirror that is as wide as the scanner plate in the axisperpendicular to the torsion bar axis. Thus, for the same size mirrorarea, a smaller moving plate can be used. The smaller moving platerequires less drive current since in general, because smaller plates areeasier to drive. Therefore, if we apply some upper bound to the drivecurrent, the smaller plate is better and, if we apply some lower limiton the operational frequency, the smaller plate is better.

The larger scan operating window also yields less critical alignmentrequirements and, for laser printing applications, a larger laser spotsize at the reflective surface of the rotating plate. A larger spot sizeat the reflective surface tends to provide a smaller laser spot size atthe image plane. This spot size relationship results from optics. When alaser beam is passed through a focusing lens, the laser beam generallyconverges to a minimum diameter near the focus of the lens dependingupon the divergence of the laser beam prior to entering the lens. For agiven wavelength and a given lens focal length, the size of the focusedspot is dependent on only one other parameter, the diameter of the beamentering the lens. A larger input beam diameter can produce a smallerresultant spot size. Thus, as the mirror in the scanning system growslarger, the laser spot that can be produced grows smaller. Therefore,for a given plate size, the print resolution can be greater with anoscillator that does not have coils on the plate.

With a small mirror (eg. a small reflective surface 246), it isdesirable to “overfill” the mirror with laser beam, so that the size ofthe reflected beam is defined by the mirror size. This alleviates thealignment of the laser relative to the scanner, and also provides for aselected portion of the beam to be reflected. This selected portion (thecentral region of the beam) will product an intensity cross section ofthe beam that is substantially more uniform than an un-truncated beam,where the intensity follows more of a “Gaussian” profile. The truncatedbeam intensity would be more of a “top hat” profile. This overfilling isnot practical with devices that have coils patterned on the oscillatingplate.

Referring now to FIG. 21, yet another embodiment of a torsion oscillator260 is shown. As shown in FIG. 21, by locating the coil(s) away from theplate 264, one or more diffractive reflective surfaces 262 can be etchedor otherwise fabricated as part of the reflective surface 266 on theplate 264. The one or more diffractive reflective surfaces 262 caninclude different diffractive properties to produce different reflectiveeffects when an energy source is directed or scanned across the plate264. The diffractive optical surfaces 262 can also provide optical powerto the plate surface in addition to the reflective surface 266. Thus, itis possible to remove a lens from the system by providing refractiveoptical power on the plate 264. For example, the diffractive reflectivesurfaces 262 may reflect light substantially like a concave ellipticalmirror, which in a particular optical system may eliminate the need forone convex lens. Also, if desired, the mirrors 262 may be curved in athird dimension.

Single Sensor Laser Scanner

In an alternative preferred embodiment of the present invention, themaximum oscillation amplitude may be determined by observing only onesensor signal. Referring to FIGS. 15, 11 and 22, it is appreciated thata single sensor, such as sensor A in FIG. 15, will create two pulses peroscillation cycle. As the amplitude of the oscillation increases, t0 andt2 will increase while t1 and t3 will decrease. For a given frequency,time intervals such as t0, t1, t2, or t3 are proportional (or inverselyproportional) to amplitude. To determine a currently existing resonantfrequency, the control logic 90 varies the electrical drive frequencyand determines a maximum oscillation amplitude by determining thefrequency at which t0 or t2 are greatest, or the frequency at which t1or t3 is smallest. Such frequency is the currently existing resonantfrequency. (Again, “or” is used as an inclusive logical operator in itsbroadest form.)

Referring to FIG. 22, there is shown a graph of two sinusoidal curves270 and 272 representing the oscillation of oscillator 50 at twodifferent amplitudes. The amplitude is shown on the Y axis and time isshown on the X axis. Line 274 represents the amplitude at which sensorA, shown in FIG. 15, will sense the reflected light beam 152. Sensor Awill generate two pulses per oscillation cycle of the oscillator 50. InFIG. 22, t-a1-sensor represents the time delay between the trailingpulse of sensor A and the next leading pulse of sensor A when theoscillator 50 is functioning as indicated by curve 274. t-a2-sensorillustrates the time delay between the trailing pulse generated bysensor A and the next leading pulse generated by sensor A when theoscillator 50 is functioning as indicated by curve 272. The curves 272and 270 of FIG. 22 are grossly exaggerated to illustrate that when theamplitude of oscillation decreases, the time delay between the trailingpulse and the leading pulse of sensor A will increase dramatically.Thus, the time indicated by t-a1-sensor is dramatically smaller thant-a2-sensor. By observing this time delay, control logic 90 determinesinformation corresponding to the amplitude of oscillation. Preferably,during a calibration process, a lookup table or formula is provided thatwill correlate the magnitude of this delay time, such as t-al-sensor, toan oscillation amplitude such as that represented by curve 274 or toinformation corresponding to oscillation information. From FIG. 22 andFIG. 15, it will be appreciated that the times, t-a1-sensor andt-a2-sensor, each correspond to the sum of t1+t2+t3 shown in FIG. 15.Thus it is appreciated that the currently existing resonant frequencymay be determined in a number of different ways, such as those describedabove, by varying the electrical drive frequency to the oscillator 50and observing the amplitude of oscillation. For many applications, it isnot necessary to physically calculate the currently existing resonantfrequency. For example, for a known mechanical operating frequency ofoscillation, the control logic 90 may observe t-a2-sensor and based onthis time, change the electrical drive frequency without calculating thecurrently existing resonant frequency. The time delay, t-a2-sensor, in asense represents the currently existing resonant frequency. The purposeand effect of changing the electrical drive frequency to place it nearthe currently existing resonant frequency may be accomplished withoutactually calculating the resonant frequency. Again, in a sense, thecurrently existing resonant frequency is indirectly observed but neverquantified.

A single sensor 280 may also be utilized to determine the direction andposition of a scanning laser 78 such as that used in the embodiment ofFIG. 9. FIG. 23 is a timing diagram that shows the operation of such anembodiment of the present invention wherein a single sensor 280 todetermine the direction and position of the scanning laser 78 is shown.The embodiment uses a single sensor 280 placed along a scan path 282 ofthe scanning laser beam. The sensor 280 is placed closer to either theleftmost scan point 284 or the rightmost scan point 286 of the scan path282. The reflective device 50 used to scan the laser beam is driven witha drive signal 288 that regularly oscillates between a high value 290and a low value 292. The drive signal 288 switches between its highvalue 290 and its low value 292 when the laser is approximately at itsleftmost scan point 284 and its rightmost scan point 286 respectively.Because of the phase shift depicted in FIG. 35, the previous statementis less and less accurate as the drive frequency nears the resonantfrequency. The scanning of the laser beam along its scan path 282 causesthe sensor 280 to produce a sensor feedback signal 294. For the sensor280 shown in FIG. 23, this feedback signal 294 has a high value 296 whenthe sensor 280 does not detect the laser beam and a low value 298 whenthe sensor 280 detects the laser beam. However, it will be appreciatedthat the actual values of the feedback signal 294 will depend upon theparticular type of sensor 280 used to detect the scanning laser beam.

A laser beam in an imaging system using an oscillating reflective device50 as its scanning mechanism continuously sweeps back and forth throughits scan as the reflective device oscillates. After sweeping the beamthrough its scan in one direction, the oscillating reflective device 50sweeps the beam back across its scan in the opposite direction toposition the beam at the start of the next scan. As previously discussedabove, this back and forth sweeping causes the beam to pass a sensor 280in its scan path twice per back and forth scan. However, if the imagingsystem utilizes a rotating polygon mirror scanner that causes the beamto jump from one end to the other, a sweep discontinuity is createdwhereby the sensor only detects the laser beam once per scan. Thus, thesingle sensor 280 located in the scan of the laser beam 84 depicted inFIG. 9 will be illuminated twice per scan if the means for sweeping thelaser beam through its scan does so in a bi-directional manner ratherthan a uni-directional manner such as created by a rotating polygonmirror. Therefore, in such an embodiment, the sensor feedback signal 294will detect the laser beam in intervals that are separated by a timespan of either t0 or t1 as shown in FIG. 23. The time between the secondsensor pulse of one scan and the first sensor pulse of the next scan isthe time required for the laser to sweep in reverse from the from thesensor 280 out to the leftmost scan endpoint 284 and then forward backto the sensor 280. This is the time t0. The time interval between thefirst and second sensor pulses of a given scan is the time required forthe beam to sweep forward across the imaging window out to the rightmostscan endpoint 286 and then back across the imaging window in reverse.This is the time interval t1. These differing time spans result from thesensor 280 being placed in a location on the scan path 282 that isoffset from the center of the scan path 282. Thus, the time span t0corresponds to the time between the laser beam passing the sensor 280 onits way to its leftmost endpoint 284 and then returning to the sensor280, and the time span t1 corresponds to the time required for thescanning laser beam to move from the sensor 280 to the right most scanpoint 286 and back to the sensor 280. If the imaging window is centeredin the scan path, the forward and reverse travel times are the same andthe sensor is preferably placed just outside of one edge of the imagingwindow, t1 will be larger than to by twice the time required for thebeam to transverse the imaging window. In such an imaging system, thesystem calculates the time required for the beam to sweep across theimaging window as (t1-t0)/2.

In order to send image data to a laser in a laser printer in anappropriate manner, the printer must know whether a given sensor pulseindicates that the beam is just starting a scan or that the beam istraveling in the opposite direction and therefore nearly finished with ascan. Placing the sensor 280 in an offset location from the center ofthe scan path allows the right/left direction of the movement of thelaser beam to be determined by examining the time periods between thesensor's detecting the scanning laser beam. As previously discussed, twosensors could be used such that the direction of the laser beam's scancould be determined by examining which sensor is currently detecting thelaser and which sensor previously detected the laser beam. However,adding a second sensor increases the cost of the imaging system and maybe undesirable in embodiments that are directed toward cost-sensitiveproducts such as laser printers.

For purposes of this discussion, the laser beam is said to be travelingforward when it sweeps across its scan from left to right and in reversewhen its sweeps from right to left. The imaging window in an imagingsystem that sweeps the laser beam with an oscillating reflective deviceis typically centered in the middle of the scan path such that theforward travel time of the beam is nominally the same as the reversetravel time. If a positional feedback sensor is positioned such that itis not centered in the scan, the time interval between sensor pulsesvaries depending upon whether the sensor pulse was generated near thebeginning or end of the scan. This difference in time periods can beused to determine the direction in which the scanning laser is moving.Thus, if the time period t0 is measured the laser beam is traveling inthe forward direction immediately after the second pulse is detected.Similarly, if the time period t1 is measured, the laser beam istraveling in the reverse direction immediately after the second pulse isdetected.

A resonant oscillating device operates efficiently at or very close toits resonant frequency. Consequently, a system utilizing a resonantoscillating device should search for the device's resonant frequencyeach time the device is started. When the resonant oscillatingreflective device in a system such as that discussed with respect toFIG. 1 is first started, its angular deflection may not be large enoughto sweep the laser beam across the sensor. The angular deflectionincreases as the drive frequency is brought closer to the resonantfrequency causing the beam's scan to increase. At some point during thesearch for the resonant frequency, the angular deflection will be justenough to illuminate the sensor. At this point, the sensor may produceeither one pulse 300 or two pulses 302 and 304 per scan at or near thisparticular drive signal 306 frequency. FIG. 24 illustrates thissituation. Uncertainty in the number of sensor pulses per scan can leadto capture times that do not correctly indicate the time required forthe beam to sweep through the corresponding physical interval.Consequently, the imaging system may falsely detect that it is at theresonant frequency unless it has a way to re-synchronize itsinterpretation of the capture values to the actual physical intervalsthey represent.

One method of avoiding this problem region is to design the imagingsystem such that it changes the frequency at which it drives theresonant oscillating reflective device by some relatively large amountonce the angular deflection is large enough for the beam to alwaysproduce two pulses per scan. This will push the drive frequency closeenough to the resonant frequency such that the angular deflection of theoscillating reflective device will cause the beam to always produce twopulses per scan. The size of the frequency increase should be chosenwith the variations in devices and operating conditions in mind. Thefrequency increase should be small enough that it will always cause thedrive frequency to be less than the resonant frequency in everydifferent device in all practical or expected operating conditions. Or,the frequency increase should be large enough that the drive frequencyis always shifted to a frequency above the resonant frequency. Ifvariation from one device to the next is such that a particular fixedchange in drive frequency could push the frequency beyond the resonantfrequency of some devices, and remain below the resonant frequency inother devices, such result could cause a subsequent search for theresonant frequency to fail. Thus, the size of the frequency increasewill change depending on the application and the variance in the devicesmanufactured.

Referring to FIG. 23, in a preferred method of determining scandirection, the first test is whether two sensor pulses are detected inone cycle of the drive signal, which may be determined by observing thetime interval between a rising edge 289 of signal 288 and the nextrising edge 293 and counting the number of pulses detected. If twopulses are detected, the direction of the scan may be determined byobserving the time intervals t0, t1 and knowing where the sensor 280 islocated. In FIG. 23, the forward travel occurs after the occurrence ofthe smaller time interval t0, which means that the laser is traveling inthe forward direction when pulse 298 is produced. The reverse traveloccurs after the larger time interval t1 is produced, which means thelaser is traveling in the reverse direction when pulse 294 is generated.These processes ensure the integrity of the data used to detect theresonant frequency and also allow the imaging system to know both beamposition and direction of travel, both of which are helpful for properimaging control.

Some imaging systems may also require the ability to detect when thelaser beam is at the end of the imaging window. Such information can beused to more accurately place the image data by allowing the imagingsystem to directly measure the time required for the beam to sweepacross the imaging window. This additional beam position feedbackinformation could also serve as a reverse start-of-image signal if thesystem is designed to image during both the forward and reverse portionsof the scan. Such imaging systems can detect when the beam is at the endof the imaging window without the aid of another sensor 308 by adding amirror 310 by which the beam is reflected back to the single positionalfeedback sensor 308. This configuration is shown in FIG. 25. Each scanwill produce four sensor pulses 312, 314, 316 and 318 per scan in thisconfiguration rather than two since the sensor 308 will be illuminatedat both ends of the imaging window and the beam crosses the imagingwindow twice per scan.

Correlating the sensor pulse capture times to the physical intervals ofthe scan is different when the sensor produces four pulses per scanbecause the asymmetry relied upon in the two pulse configuration is nolonger present. However, the sensor interval validation requirements ofthe two-pulse system can be extended to the four-pulse configuration.Thus, in such an embodiment, the imaging system normally receives fourpulses per scan with two pulses occurring when the drive signal for thereflective device is high and two pulses occurring when the drive signalis low. However, such condition may not always occur due to phase shiftsbetween the drive signal and the sensor signal. In any event, thisinformation alone will not completely guarantee that each sensor pulseinterval capture time can be associated with a particular physicalportion of the scan. When the device is close to its resonant frequency,the first sensor pulse received after the rising edge of the drivesignal, or falling edge depending upon the imaging system design, may becorrectly interpreted as the pulse generated by the beam as its travelsforward into the imaging window. But, when the resonant frequency searchis in progress and the resonant oscillating reflective device is notclose to its resonant frequency, the sensor pulses will not always havethe same phase relationship with the drive signal edges as that in theembodiment shown in FIG. 25. In FIG. 26, the first sensor pulse 320 thatoccurs after the drive signal rising edge 322 is actually generated asthe beam hits the mirror at the end of the imaging window. The capturevalues cannot be correlated to a particular physical interval in thissituation.

The capture times associated with a given physical scan interval willeither increase or decrease as the resonant oscillating reflectivedevice, such as scanning member 336, is driven closer to its resonantfrequency depending on the particular scan interval chosen. The imagingsystem can therefore ensure that an interval measurement corresponds tothe assumed physical scan interval by performing a slope check on eachinterval measurement as the drive frequency changes during the searchfor the resonant frequency. For example, referring to FIG. 25, if thefrequency of the drive signal is moving towards its resonant frequency,t0 should be increasing. To find t0, the processor 330, shown in FIG.27, moves the frequency in a direction known to be towards the resonantfrequency and time intervals between sensor pulses are measured. Thetime interval that is increasing is identified as t0 and the timeinterval that is decreasing is identified as t1. If the frequency ismoving away from the resonant frequency, t0 should be decreasing. Byadding this check to the other requirements previously mentioned for afour pulse configuration, the imaging system can validate the sensorpulse capture times. This validation ensures the integrity of the dataused to detect resonant frequency and allows the imaging system to knowboth the beam position and direction of travel. This improves control ofthe imaging system.

A block diagram of the components needed to implement a preferredembodiment of the present invention utilizing a single sensor is shownin FIG. 27. A processor 330 may be one or more different logic devices,such as an ASIC or programmable logic, and it controls a drive signalgenerator 334. The drive signal generator 334 produces a drive signalthat controls the motion of a scanning member 336. The processor 330receives output pulses from a sensor 332 that is positioned along a scanpath of the scanning member 336. The sensor 332 produces output pulseswhen the scanning member 336 scans across particular locations along itsscan path. When the processor 330 detects an output pulse from thesensor 332, it records a corresponding time received from the clock 338.When the processor 330 receives another output pulse from the sensor332, the processor examines the clock's 338 output and calculates thetime interval between the received sensor pulses. After a number ofiterations, two distinct alternating time intervals will becomeapparent. The larger of the time intervals will correspond to a forwardor reverse scan direction and the smaller of the time intervals willcorrespond to the opposite scan direction. The actual time intervalrelationship will depend upon the particular construction of the deviceand can be determined experimentally and recorded in a memory 340. Forexample, one may determine that the first time interval after eachrising edge of the drive signal is t0. By observing the time intervalsthemselves, two candidate time intervals can be selected as possible tointervals. By referencing the rising edge of the drive signal underknown operating conditions, primarily known drive frequencies andamplitudes, the candidate t0 intervals can be narrowed to one, and theactual t0 is identified. The processor 330 can also examine the timeintervals and compare them to a set of reference values in the memory340 to determine whether or not the scanning member is operating at itsresonant frequency. If it is not, the processor 330 can instruct thedrive signal generator 334 to alter the frequency of the drive signalsuch that the scanning member 336 operates at its resonant frequency.Alternatively, the drive signal generator 334 can alter the amplitude ofthe drive signal to produce a scan path of a desired size.

Bi-directional Printing

The scanning system of the present invention, such as shown in FIGS. 9,10, 13 or 12 for example, may be used in a bi-directional mode ofoperation. That is, the laser is turned on and functions in bothdirections as it moves through a scan path. In the bi-directional mode,it is preferred to use a system having two sensors, such as sensors Aand B shown in FIG. 9, but a single sensor system may be used ifdesired. The bi-directional mode of operation is best understood byreference to FIGS. 28, 29 and 30 which graph scan angle (or scanposition) versus time for a scanning a laser beam such as beam 152 (FIG.13). Since the motion of the beam 152 and the oscillator 50 areproportional, these Figures may represent the motion of either or both.

FIGS. 28, 29 and 30 are similar to FIGS. 15, 11, 22, 17, and 25, forexample, and will not be described in detail to avoid repetition. FIG.28 shows a sine wave representing oscillation of either laser beam 152or oscillator 50. FIG. 29 is a schematic representation of a laser beam152 sweeping through a scan across sensors A and B. FIG. 30 is a timingdiagram showing the time relationship between sensor feedback signalsand signals indicating the start of forward beam travel. In thesefigures, t-forward represents the forward print window of the scanninglaser beam 152 and t-reverse represents the reverse scan of the beam152. The reverse operation that occurs during t-reverse is similar tothe forward operation, except the data is reversed. For example, in aprinting operation, the last pel is printed first and the first pel isprinted last as the laser beam 152 scans in the reverse direction.

Referring to FIGS. 28, 29 and 30 simultaneously, for bidirectionalprinting, the laser beam travels across sensor A moving to the leftuntil it reaches the leftmost scan endpoint. Beam 152 then travels fromleft to right and crosses sensor A at angle a, which creates a sensorpulse. The laser beam 152 then travels a short distance and reaches thebeginning of the forward print window. The time required to cross theforward print window is designated as t-forward. Beam 152 then leavesthe forward print window and after a short distance, it crosses sensor Bat position b (angle b) and it continues its left to right travel untilbeam 152 reaches its rightmost position. The beam 152 then reverses itstravel and moves right to left crossing sensor B again and then crossingthe reverse print window during the time period, t-reverse. The laserbeam 152 then reaches sensor A and the cycle repeats. As the beam 152crosses the forward and reverse print windows, it images or prints.

During a laser scan, preferably the time periods represented by thesubstantially linear regions (t-forward and t-reverse) are used forprinting in the preferred embodiment resulting in less than half of thescan period (the time to complete one full laser scan) being used forprinting. In other less preferred embodiments, t-forward and t-reversemay encompass times during which the curve 350 (FIG. 28) is notsubstantially linear. In such embodiment, a lens such as lens 150 (FIG.13), may be used to create a substantially constant scan speed of laserbeam IS across the drum 96, for example. Using both the substantiallylinear and the non-linear portions of curve 350 allows greater scanefficiency, but the lens 150 becomes more difficult to design and moreexpensive. Even embodiments using a substantially linear portion ofcurve 350, a lens 150 is or may be used to correct for even slightnon-linear sections and thereby create a constant speed scan of beam152, but such lens is typically less difficult to design and lessexpensive.

The scan efficiency, η, is defined as the ratio of the usable print time(t-print) to the total scan time (t-scan). For imaging in only one scandirection of the light beam, the total usable print time will equal theforward print time (t-print=t-forward), and the scan efficiency, η, isapproximately 25%. The scan efficiency of a rotating polygon mirror istypically in the range of 65%–75%. Since the scan efficiency of a galvoscanning system 154 during uni-directional printing is typically lowerthan the scan efficiency of a rotating polygon mirror, higher scanspeeds and frequencies typically are required for the galvo scannersystem 154 to achieve the same print speed in PPM as the rotatingpolygon mirror.

A galvo scanning system also typically requires a higher video data rate(approximately 3 times greater than a rotating polygon mirror) because ashorter window of time is available during each scan to write the latentimage at the same number of scans per second. By printing in both scandirections, the usable print time per scan is approximately doubledresulting in an increase in the scan efficiency to approximately 50% ina typical embodiment and a reduction in the data rate requirements isachieved. Additionally, image control, or gray scale implementation,requires multiple slices per PEL which increases the required video datarate. Bi-directional printing reduces the required video data rate anddoubles the image control capability as compared to a system utilizingunidirectional printing.

Generally, higher scan frequencies increase the difficulty of the galvoscanner design. As discussed above, the extensions 54 a, 54 b and plate52 (FIG. 1) constitute a rotational spring-mass system with a specificresonant frequency. The resonant frequency of a galvo scanner includinga torsion oscillator such as torsion oscillator 50 (FIG. 1), 64 (FIG. 2)or 70 (FIG. 5) is primarily a function of the size of mirror 60 and theextensions 54 a, 54 b. The mass of plate 52 is significantly affected bythe size of mirror 60 and the torsion bar extensions 54 a, 54 b controlthe spring rate. For reliability, the torsion bar extensions 54 a, 54 bmust be designed to stay within an acceptable limit of stress for agiven maximum amplitude of rotation. However, the extensions 54 a, 54 balso need to possess increased stiffness to raise the resonant frequencyof the galvo scanner thus achieving higher print speeds. Therefore,higher resonant frequencies tend to require lower total mechanicalamplitude of oscillations from the torsion oscillator 50, 64 or 70 tokeep the stress upon the extensions 54 a, 54 b at an acceptable level.Bi-directional printing reduces the required resonant frequency byapproximately half to achieve the same print speed performance; thus itdoubles the upper PPM limit that the system can achieve with a givengalvo scanner design.

The operation of a bi-directional embodiment is illustrated in FIGS. 30and 31. FIG. 30 illustrates the combined sensor feedback'signals fromsensors A and B as a function of time. In a preferred embodiment, eithersensor A or B or both comprise a photodiode that is biased up involtage. Preferably, the biased voltage (V-reference) is +5V or +3.3V.When the reflected light beam 152 travels over either sensor A or B, thevoltage output of the sensor drops toward zero as shown in FIG. 30. Inthe alternative embodiment wherein sensor B comprises a mirror, thereflected light beam 152 is reflected by the mirror at location b to thesensor A and the voltage output of sensor A drops toward zero.Alternatively, sensor A could comprise a mirror while sensor B comprisesanother type of sensor such as a photodiode.

A signal indicating the start of forward beam travel (from point ctoward point d in FIG. 29) is shown at the top of FIG. 30. The signalindicating the start of forward beam travel is preferably generated fromthe electrical drive signal to the coils 58 of the torsion oscillator50, 64 or 70. When a forward electrical drive signal is sent to thecoils 58, a signal is generated indicating the start of forward beamtravel. Likewise, when a reverse electrical drive signal is sent tocoils 58, a reverse drive signal is or may be created to indicate thestart of reverse beam travel. In a less preferred embodiment, when twosensors A and B are used, direction of travel may be determined by theorder of the signals from the two sensors, where A to B is one directionand B to A is the other.

FIG. 31 depicts a block diagram of the control logic 370 forbi-directional printing. The control logic 370 receives signals fromsensors A and B and from a is drive signal generator 376 and providessignals to Video Control 378 to control the timing of an imaging orprinting function. In a preferred embodiment, the control logic 370 isincluded in control logic 90 and both may be implemented by a singlemicroprocessor, although separate logic may also be employed. Also, inthe preferred embodiment active low logic is used, meaning theoccurrence of an event is signified by a signal going low, typicallynear zero. A sensor output on line 372, Hsyncn 1 from sensor A, and asensor output on 374, Hysncn 2 from sensor B, are combined in AND gate380 to form the sensor feedback signal 360, also shown in FIG. 30. Thesensor feedback signal 360 from the AND gate 380 is sent on line 392into an OR gate 382 along with a SZCC signal on line 384 from a scanzone counter control (SZCC) circuit 386. The SZCC output signal on line384 equals V-reference when the next sensor pulse should not trigger ascan. For instance, referring to FIG. 13, when the reflected light beam152 is traveling from sensor B2 to sensor A2, the next sensor pulse willoccur when the reflected light beam 152 crosses sensor A2. This sensorpulse should not trigger the reflected light beam 152 to scan the printdata from the RIP buffer 388 (FIG. 32) because the reflected light beam152 is traveling toward endpoint c and is not within the linear printzone, t-forward. When the SZCC output signal on line 384 is V-reference,the output 390 of the OR gate 382 is also V-reference even when the nextsensor pulse arrives on line 392. Thus, as the next sensor pulse sendsthe sensor feedback signal on line 392 near zero volts, the SZCC outputsignal 384 stays at V-reference and the resulting output 390 from the ORgate 382 also remains at V-reference.

The SZCC output signal 384 is driven low (near zero volts) when the nextsensor pulse is received to thereby to scan the print data from the RIPbuffer 388. To continue the example from above, as the reflected lightbeam 152 travels from sensor A at location a to the scan endpoint c andreverses scan direction back toward sensor A, the next sensor pulse(when the reflected light beam crosses sensor A) should trigger thereflected light beam 152 to scan the print data from the RIP buffer 388because the reflected light beam 152 is about to enter the forward printzone represented by the time period t-forward. The next sensor pulsefrom the sensor feedback signal on line 392 will be near zero volts andthe SZCC output signal 384 will be low, and the output 390 of the ORgate 382 is then also low (near zero volts), which is a signal to beginimaging or printing.

The output 390 of the OR gate 382 is transmitted to a video control 378.Preferably, the video control 378 is active low logic so a falling edgeis interpreted by the video control 378 as an HSYNC (horizontalsynchronizing) signal. An HSYNC starts the data output from the RIPbuffer 388 after an appropriate time delay equal to the time, forexample, from the beginning of the t1 zone to the start of the t-forwardzone (referred to as t-delay forward). Similarly, the time delay in thereverse direction may equal the time difference between the beginning ofthe t3 zone and the start of the t-reverse zone (t-delay reverse). It isalso understood that t-delay forward and t-delay reverse may comprisevalues which result in the print data being written from the RIP buffer388 at various times after the reflected light beam 152 enters intoeither time period t-forward or t-reverse. Thus, t-delay forward andt-delay reverse may be used to achieve various desired printcharacteristics such as margin control. To successfully align themargins for each scan direction in bi-directional printing, t-delayforward for scanning and writing the print data in the forward directioncan be set to a different value than t-delay reverse for scanning andwriting the print data in the reverse direction. Varying t-delay forwardfrom t-delay reverse also corrects for variance in offset, x, or otherlack of symmetry in the torsion oscillator scan shape.

For uni-directional printing, the RIP buffer 388 is loaded inconventional fashion with each line in the same scan direction. Inuni-directional printing, the only sensor pulse which should trigger thewriting of the print data is the sensor pulse at the end of the t0region when the reflected light beam 152 passes sensor A. In thisembodiment, the SZCC output on line 384 remains at V-reference until thenext sensor pulse is generated at the end of the t0 region as describedabove. After the reflected light beam 152 has passed sensor A and istraveling toward scan endpoint c but prior to the reflected light beam152 passing sensor A again, the SZCC output 384 is driven low. Thus, asthe next sensor pulse is transmitted as a sensor feedback signal on line392 (when the reflected light beam 152 passes sensor A again) to the ORgate 382, the output 390 of the OR gate 382 goes low and an HSYNC signalis generated directing the reflected light beam 152 to begin writing theprint data from the RIP buffer after the time delay, t-delay forward.Only the t-delay forward value is needed for uni-directional printing.To print bi-directionally, during both t-forward and t-reverse, theprint data is loaded in the RIP buffer with alternate lines in oppositedirections so that the final imaging is correctly arranged duringbi-directional printing.

Referring to FIG. 32, one form of a RIP buffer 388 is schematicallyshown. Preferably the RIP buffer 388 is part of the video control 378.Video data is introduced on line 420 and is received by a switch 422within the buffer 388. The switch 422 is controlled by a data controlsignal received on line 424 and is produced by the video control 378.When the forward video data is being received, the switch 422 directsthe data through line 426 and when reverse video data is received, theswitch 422 directs the video data through line 428. Forward memory 430is connected to line 426 to receive the forward video data and a reversememory 432 is connected to reverse memory line 428 to receive thereverse video data. In FIG. 32, line 428 is shown connected to theopposite end of the memory 432 as compared to memory 430 and line 426.This feature graphically illustrates that reverse video data is storedin the reverse memory 432 in a reverse order as compared to data inmemory 430. Data is read from the memories 430 and 432 through lines 434and 436 under the control of switch 438. A serialization directionsignal is supplied on line 440 to actuate the switch 438, which causesthe buffer 388 to write either the forward video data or the reversevideo data. When switch 438 is connected to line 434, the output signalon line 442 is the forward video data. Likewise, when switch 438 isconnected to line 436, the reverse video data is written on line 442.Since the video data in the reverse memory 432 was stored in reverseorder, it is written in reverse order on line 442 and is printed inreverse order during the reverse beam travel indicated by t-reverse. Itshould be understood that FIG. 32 is a somewhat schematic graphicalrepresentation of buffer 388 designed to illustrate the principles ofthis embodiment. The buffer 388 could be implemented differently indifferent embodiments. For example, buffer 388 could have one memorythat is used serially to hold both forward and reverse data with thereverse data being written in reverse order. In another embodiment, oneor two memories maybe used and the reverse data is stored in memory inthe same order as the forward data, but it is retrieved from memory in areverse order.

Referring again to FIG. 31, the sensor feedback signal on line 392 isgenerated as the output of the AND gate 380 which has two input lines372 and 374. In this embodiment, input line 372 receives the output ofsensor A which comprises a photodiode that generates a horizontalsynchronizing signal (HSYNC1). Similarly, input line 374 receives theoutput of sensor B, a photodiode generating a separate horizontalsynchronizing signal (HSYNC2).

In an alternative embodiment, the input lines 372 and 374 (outputs ofsensors A and B respectively) are connected together. The AND gate iseliminated and one less input is required to a capture timer logic 394.This embodiment results in lower cost cabling.

In another embodiment, one sensor comprises a mirror. Either sensor A orsensor B could comprise a mirror, but for purposes of illustrationsensor B comprises the mirror. As the reflected light beam 152 passesover sensor B, the mirror reflects the light beam 152 to sensor A. Theresulting output of sensor A is the same combined sensor feedback signalshown in FIG. 30 with the same information content. Again, the AND gateis eliminated and the sensor cost is cut in half.

Still referring to FIG. 31, the inputs 372 and 374 (generated from anyof the embodiments discussed above) are also fed into a capture timerlogic 394. Capture timer logic 394 time counts each of the timeintervals t0, t1, t2, and t3 shown in FIGS. 28 and 30. When thereflected light beam 152 travels over sensor A or sensor B the capturetimer logic 394 receives a falling edge, as shown in FIG. 30 and stops atime count in progress. Timer logic 394 then transmits the time countthrough capture timer output signal 396 and transmits a signal 398indicating it is transmitting a new capture. Thus, each time the nextsensor feedback pulse is received by capture timer logic 394, the newcapture signal on line 398 is toggled.

In the preferred embodiment, the capture timer logic 394 does notrecognize which time interval has been measured (either t0, t1, t2, ort3). As shown in FIG. 31, a capture control logic 400 receives theinformation content of a drive signal generator 376 through line 404.One function of capture control logic 400 is to generate a capture errorsignal on line 406 and capture time signals for each sensor intervalsignal on line 408. Although the signals on lines 406 and 408 are shownas transmitted to control logic 90 in FIG. 31, it is understood that allof the components of FIG. 31 may be contained within control logic 90 ormay be external to control logic 90.

The capture control logic 400 also uses the information content of thedrive signal 404 from the drive signal generator 376 to generatedirection information needed for either bi-directional or unidirectionalprinting. The direction information (forward or reverse) is used toprovide the SZCC output signal on line 384 (which synchronizes theoutput on line 390 of the OR gate 382 with the start of forward orreverse scan direction) and is used to generate a serializationdirection signal on line 410 to transmit to the video control 378 fordetermining forward or reverse serialization direction from the RIPbuffer 388.

In one embodiment, the drive signal generator 376 provides a square wavesignal on line 404 to drive the current to the coils 58 of the torsionoscillator 50, 64 or 70 such that half of the square wave (e.g. thepositive half) drives the torsion oscillator 50, 64 or 70 in onedirection, for example the forward direction, and the other half (e.g.the negative half) of the square wave signal drives the torsionoscillator 50, 64 or 70 in the opposite direction. The capture controllogic 400 detects a rising or falling edge of the square wave drivesignal 404, whichever corresponds to the start of forward direction oftravel of the torsion oscillator 50, 64 or 70, and generates a startforward travel signal on line 412 indicating start of forward beamtravel also shown in FIG. 30. As previously discussed with regard to theembodiment of FIG. 25, one may not assume that a rising edge of thedrive signal 404 indicates that the oscillator 50, 64 or 70 is moving inthe forward direction. However, by analyzing the time intervalsthemselves and using experimentally determined relationships between thetime intervals and the drive signal 404, the capture control logic maydetermine which pulse is the first pulse in the forward travel of thelaser. This method was discussed above. The capture control logic 400uses the same method as described above to determine the first sensorpulse occurring while the laser is moving in the forward direction.

The start forward travel signal on line 412 is sent to the SZCC 386 andis also used within the capture control logic 400 to reset a counterthat counts new captures. The first and second new captures after thestart of forward travel correspond to the forward direction part of thescan (as the reflected light beam passes over sensor A and sensor B asdenoted by time period t1) and the third and fourth new capturescorrespond to the reverse direction of the scan (as the reflected lightbeam again passes over sensor B and then sensor A as denoted by timeperiod t3).

For bi-directional printing, the serialization direction signal on line410 is provided to the video control 378 to control the direction ofdata from the RIP buffer 388 (to ensure correct alignment of the printdata). The serialization direction signal is set high for the first andsecond new captures (denoting forward beam travel) and is set low forthe third and fourth new captures (signaling reverse beam travel). Foruni-directional, printing, the serialization direction signal on line410 is always in one orientation (high for example) as the direction ofserialization of the RIP buffer is always the same in uni-directionalscanning.

In an alternative embodiment, the drive signal generator 376 generatesthe start of forward beam travel signal 412 as described in theembodiment above. Instead of counting new captures to toggle theserialization direction signal on line 410 to the video control 378, thedrive signal 404 can be buffered and sent either directly or as itslogical inverse (depending upon the forward and reverse sign conventionof the torsion oscillator 50, 64 or 70) as the serialization directionsignal 410 to the video control 378.

In another embodiment, sensor A and sensor B generate separate HSYNCN1and HYSNCN2 signals on lines 372 and 374 respectively and the capturecontrol logic 400 determines the start of forward travel by recognizingwhich sensor (either A or B) is generating which time intervals. Forexample, sensor A generates HYSNCN1 at the start of time periods t1 andt0 while sensor B generates HSYNCN2 at the start of time periods t2 andt3. By comparing the time intervals t0 and t1 from HSYNCN1 anddetermining the smaller interval, the capture control logic recognizesthat essentially half the time of the smaller time interval (t0/2) afterthe start of the time interval t0 is the start of forward travel. Atapproximately half the time of the smaller time interval (t0/2), thereflected light beam 152 has reached the scan endpoint c and isreversing scan direction to begin the forward beam travel. Therefore,the capture control logic 400 can generate the start of forward beamtravel signal 412 to be sent to SZCC 386. The serialization directionsignal 410 provided to the video control 378 to control the direction ofserialization of the data of RIP buffer 388 is generated in the samemanner as discussed above.

Referring to FIG. 31, the start forward travel signal on line 412 andthe new capture signal on line 398 are input into the scan zone countercontrol (SZCC) 386 to generate the SZCC output signal on line 384. TheSZCC output signal 384 is based upon whether a bi-directional enable(BIDI-enable) signal on line 424 to SZCC 386 is high or low. If thebi-directional enable signal high, bi-directional printing is desiredand it is low, uni-directional printing is desired. When a start forwardtravel signal on line 412 is received by the SZCC 386, the SZCC 386 isreset and the SZCC output signal 384 is set to voltage low. At thistime, the sensor feedback signal on line 392 is at V-reference, and theoutput signal 390 of the OR gate 382 remains at V-reference until thenext sensor feedback signal on line 392 goes low and indicates a fallingedge to the OR gate 382. When sensor feedback signal 392 indicates afalling edge (the reflected light beam 152 passes a sensor and generatesa falling voltage signal), the suppress Hsync signal on line 384 is setlow and the low signal on line 392 is allowed to pass through the ORgate 382 to become the output signal on line 390 (low) which istransmitted to the video control 378 indicating that the reflected lightbeam 152 should write the print data from the RIP buffer 388 aftert-delay forward. This signals the start of the time interval t1 that isthe desired zone for forward printing. The SZCC 386 then counts newcapture toggles through new capture signal on line 398, and the SZCCoutput signal on line 384 is reset to V-reference to ensure that thesensor feedback signal 392 at the end of the t1 interval (which would below because the reflected light beam passed sensor B) is not passedthrough as the output signal on line 390 of the OR gate 382 and is notpassed to the video control 378.

If the bi-directional enable logic line 424 is high, after the secondnew capture pulse is received by the SZCC 386, the SZCC output signal online 384 is set to voltage low. As the reflected light beam passessensor B at the start of interval t3 during reverse beam travel, thenext sensor feedback signal 392 indicating a falling edge arrives at theOR gate 382 and is allowed to pass through as the output signal on line390 of the OR gate 382 and is allowed to pass to the video control 378.This signals the start of the time interval t3 and indicates that thereflected light beam 152 should write the print data from the RIP buffer388 in the reverse scanning direction. Correct alignment of the data inreverse order is assured through the serialization direction signal 410.

If the bi-directional enable logic line 424 is low, when a start offorward beam travel signal 412 is received by the SZCC 386, the SZCC 386is reset and the SZCC output signal on line 384 is set to voltage low.After the SZCC 386 is reset, when the first new capture pulse isreceived by the SZCC 386, the SZCC output signal 384 is set toV-reference as in the case of bi-directional printing described above,but the SZCC output signal remains at V-reference through the reversetravel region. Therefore, only the first sensor feedback signal on line392 indicating a falling edge that arrives at the OR gate 382 is allowedto pass through as the output signal on line 390 of the OR gate 382 tothe video control 378. This signals the start of the time interval t1that is the desired zone for forward printing only.

While it is not the preferred embodiment, it is recognized thatbidirectional printing may be implemented in single sensor embodiments.Referring to FIG. 30, when a single sensor is used, such as sensor A, asensor input signal will be received only twice per cycle. Thus, thesensor signals that are labeled “beam at mirror” will not be present ina single sensor embodiment. Thus, in a single sensor embodiment both theforward print window and the reverse print window are located based on aknown time delay after to. The start of the forward print window isdetermined to be t-delay after t0. The start of the reverse print windowis determined to be a predetermined reverse time delay after t0. Thistime delay will change with changing operating conditions. During acalibration process, a lookup table is created and stored in memory toprovide a plurality of different forward and reverse time delays for aplurality of different operating conditions. Referring to the discussionabove in connection with FIG. 22, it will be recalled that the amplitudeand frequency of a curve representing a laser scan pattern may bedetermined using a single sensor. Once the curve is known, the reverseprint time delay may be calculated.

The dynamic physical offset, which was discussed in connection with FIG.17 complicates the calculation of the reverse time delay. However, oncethe offset, and t0, t-total are known, the reverse print time delay maybe calculated with precision. However, from a practical standpoint, alookup table is provided during a calibration process, and the lookuptable correlates t0, t-total, and the reverse time delay. Thus, thecontrol logic 90 determines the forward and reverse time delays bydetermining to and t-total and looking up the forward reverse timedelays in the table.

The two-sensor embodiment is preferred over the single sensor embodimentbecause it is believed to be more stable. Also, the two-sensorembodiment provides a level of redundancy. If one sensor of a two sensorsystem is malfunctioning, such as by providing pulses at odd times, thecontrol logic 90 may detect the malfunctioning sensor by comparing it tothe properly functioning sensor. In addition, once the malfunctioningsensor is identified, it may be disabled and the other sensor may beused to continue printing in both unidirectional and bi-directionalmodes using the procedures described above.

Use of Multiple Oscillators Operating in Tandem

As discussed in some detail above, the highest scan amplitude for agiven drive signal level, and therefore the most efficient way to exciteand operate an oscillator such as the torsion oscillator 50 occurs atthe resonant frequency of the device. This is because the oscillator 50is an underdamped second order electromechanical bandpass filter for thedrive signal entering it. Furthermore, as generally discussed withrespect to FIG. 8, the resonant frequency of a device varies with anumber of conditions such as temperature. More particularly, FIG. 33shows four graphs 450, 452, 454 and 456 of a scan amplitude 458 indegrees versus drive frequency 460 in Hertz for a particular oscillator50 and laser 78 at four different temperatures. In this very lightlydamped device, drive frequencies higher or lower than the resonantfrequencies cause inefficiency and, thus, the scan amplitude 458 quicklydeteriorates. The four graphs 450, 452, 454 and 456 respectivelycorrespond to the scan amplitude 458 versus the drive frequency 460 forthe oscillating scanner at four different temperatures of 15° C., 25°C., 45° C., and 60° C. The graph 450 shows that the maximum scanamplitude at 15° C. occurs at 2569 Hz for the particular oscillatingscanner of FIG. 33. The frequency that corresponds to the maximum scanamplitude is the resonant frequency of the oscillating scanner. If thedrive frequency 460 moves away from the resonant frequency, the scanamplitude 458 of the graph 450 decreases. Thus, for a drive signalhaving a constant drive level, the maximum scan amplitude occurs at theresonant frequency of the oscillator 50.

The graph 452 showing the relationship between the scan amplitude 458and drive frequency 460 when the oscillating device is at 25° C.illustrates that the resonant frequency is at 2568.5 Hz when thetemperature of the device is 25° C. Thus, as the oscillating devicewarms from 15° C. to 25° C., the resonant frequency of the device falls0.5 Hz from 2569 Hz to 2568.5 Hz. This relationship is furtherillustrated by graphs 454 and 456 that show that as the temperaturerises from 25° C. to 45° C. and then from 45° C. to 60° C., the resonantfrequency drops from 2568.5 Hz, to 2567 Hz, to 2566 Hz respectively.Thus, for the oscillator 50 of FIG. 9, the resonant frequency of theoscillating scanner drops as its temperature increases.

Referring now to FIG. 34, a graph showing an operating bandwidth for apreferred embodiment of the present invention is shown. The graphillustrates the scan amplitude 470 versus the drive frequency 472 for anexemplary oscillator 50 of FIG. 9. The resonant frequency 474 of theoscillator 50 occurs at 2568.5 Hz at which point the scan amplitude 470is equal to approximately 29.91 degrees. When the drive frequency 472drops to 2564 Hz., the scan amplitude 470 drops to 21.15 degrees.Likewise, when the drive frequency 472 rises to 2573.5 Hz., the scanamplitude 470 drops to 21.15 degrees. This illustrates that a sufficientscan amplitude can be generated by an oscillator 50 when the frequencyof the electrical drive signal is varied plus or minus 4.75 Hz from thepreferred resonant frequency of 2568 Hz. When driven up to 4.75 Hz awayfrom the resonant frequency, the amplitude of the scan oscillation isreduced by about 30%. However, compensation for this reduction in thescan amplitude of the oscillating scanner is achieved by increasing theamplitude of the drive signal by approximately 41%. Thus, a properlydesigned resonant oscillator 50 in accordance with a preferredembodiment of the present invention has an appropriately wide operatingbandwidth that is defined as an approximately 30% amplitude reductionover a 9.5 Hz bandwidth. This allows scan amplitude compensation fordrive frequencies other than resonant frequency to be accomplished byadjusting the amplitude of the drive signal to reasonable drive levels.Consequently, multiple scanners with differing oscillating frequenciesdue either to device specific properties or through variations inenvironmental conditions can be sufficiently matched by driving all thedevices to a single nominal frequency or sufficiently narrow band offrequencies and adjusting the amplitude of the drive signals provided toeach scanner as needed. Thus, the entire set of grouped oscillatingscanners now acts as one scanner at the common reference frequencyselected for that printer.

Referring now to FIG. 35, a graphic representation of the phase shiftbetween the drive signal and the scanning member that occurs around theresonant frequency 476 is shown. The phase shift 482 between theoscillating scanner and the drive signal and is shown on the y-axis indegrees and the drive frequency 484 is shown on the x-axis in Hertz.Because of these phase shifts, preferred embodiments of the presentinvention utilize independent phase control of each oscillator 50. Theedges 478 and 480 of the bandwidth of the oscillator 50 indicate thatthe lowest frequency 478 in the bandwidth corresponds to a minus 45degree shift from the resonant frequency 476 and the highest frequency480 corresponds to a minus 135 degree shift from the resonant frequency476. Thus, if amplitude adjustment of the drive signal is implemented asdiscussed above, phase adjustment of the drive signals is alsopreferably implemented to ensure that the oscillating scanners areoperating in tandem. Phase adjustment can be used to implement a partialpel process adjustment of registration among color planes. Usually,phase adjustment is performed to achieve equal phase relationshipsbetween the oscillating scanners, but one may also adjust phase toachieve a desired relationship between the phases of the individualscanners. In some applications, a phase shift between the oscillatingscanners may be desirable.

Referring now to FIG. 36, a block diagram for implementing a preferredembodiment of the present invention is shown. The embodiment uses fouroscillating scanners 490, 492, 494 and 496 such as would be found in alaser printer that produces color images from three primary colors andblack. While four oscillating scanners are shown, it will be readilyappreciated that the present invention could be used to synchronize anynumber of oscillating scanners. The embodiment includes a controlcircuit 498 that determines the resonant frequency for each oscillatingscanner 490, 492, 494 and 496. The control circuit 498 then selects adrive signal frequency based upon the resonant frequencies of theoscillating scanners 490, 492, 494 and 496. The drive signal frequencycan be selected in a number of different ways. For example, the drivesignal frequency may be selected to be equal to the average or mean ofthe resonant frequencies of the four oscillating scanners 490, 492, 494and 496. Selecting the average resonant frequency is beneficial in thatit reduces the average of the differences between any single oscillatingscanner's 490, 492, 494 and 496 resonant frequency and the drive signalfrequency. Alternatively, the drive signal frequency might be selectedto be the midpoint between the lowest resonant frequency of anyoscillating scanner 490, 492, 494 and 496 and the highest resonantfrequency of any oscillating scanner 490, 492, 494 and 496. This type ofselection scheme achieves the smallest possible value for the extremevariation between a scanner 490, 492, 494 and 496 resonant frequency andthe common drive signal frequency.

Once a drive signal frequency has been selected, a drive signalgenerator 500 is prompted to produce a drive signal having the selectedfrequency. The drive signal from the drive signal generator 500 isprovided to each of four drive signal amplitude adjustment circuits 502,504, 506 and 508. The drive signal amplitude adjustment circuits 502,504, 506 and 508 preferably adjust the amplitude of the drive signalbased upon the difference between the resonant frequency of theoscillating scanner to which the drive signal amplitude adjustmentcircuit corresponds and the drive signal frequency. The purpose of theamplitude adjustment is to insure that the scan amplitudes of theoscillating scanners 490, 492, 494 and 496 are all approximately equal.In alternative embodiments, the amplitude of the drive signal for eachoscillating scanner 490, 492, 494 and 496 may be determined by examiningthe scan amplitude sensed for each oscillating scanner 490, 492, 494 and496 by an associated feedback sensor 510, 512, 514 and 516. Once theamplitude of the drive signal for each oscillating scanner 490, 492, 494and 496 is adjusted by the associated drive is signal amplitudeadjustment circuit 502, 504, 506 and 508, the phase of the drive signalfor each oscillating scanner 490, 492, 494 and 496 is adjusted by adrive signal phase adjustment circuit 518, 520, 522 and 524 associatedwith each oscillating scanner 490, 492, 494 and 496. The phase of thedrive signal is adjusted to insure that all of the oscillating scanners490, 492, 494 and 496 are operating in unison. The phase adjustments canbe made based upon a detected operating phase of the oscillatingscanners 490, 492, 494 and 496 as detected by the associated feedbacksensors 510, 512, 514 and 516. Alternatively, the phase adjustment canbe made based upon the difference between the calculated resonantfrequency of the particular oscillating scanner 490, 492, 494 and 496,the frequency of the drive signal and the phase relationship discussedabove with respect to FIG. 35. Once the phase of the drive signal foreach oscillating scanner 490, 492, 494 and 496 has been adjusted by theassociated drive signal phase adjustment circuit 518, 520, 522 and 524,the phase and amplitude adjusted drive signals are used to drive theoscillating scanners 490, 492, 494 and 496. The scan amplitude of theoscillating scanners 490, 492, 494 and 496 is detected by the associatedfeedback sensors 510, 512, 514 and 516. The feedback sensors 510, 512,514 and 516 may also detect the phase of the oscillating scanners 490,492, 494 and 496. The information from the feedback sensors 510, 512,514 and 516 may then be used by control circuit 498 to further adjustthe amplitude and phase of the drive signals as needed.

FIG. 37 illustrates a preferred method of ensuring that each of multipleoscillating scanners is operating at the same process speed. The methodbegins in block 530 by determining a resonant frequency for eachoscillating scanner 490, 492, 494, 496. The resonant frequencies can bedetermined in the manners previously discussed. In block 532, a drivesignal for the oscillating scanners is generated based upon thedetermined resonant frequencies of the oscillating scanners. The drivesignal frequency is preferably chosen to be the average of the resonantfrequencies of the oscillating scanners. However, any of the previouslydiscussed methods for determining a drive signal frequency based uponthe resonant frequencies of the oscillating scanners may be used. Oncethe drive signal has been generated, the drive signal is applied to theoscillating scanners 490, 492, 494, 496 and the scan amplitude of eachoscillating scanner is measured as shown in block 534 using one of thepreviously described techniques. Drive amplitude may be indirectlydetermined by measuring t0, t1, t2 or t3 as previously discussed. Sincethe resonant frequency is the frequency at which the highest scanamplitude is produced for a given drive signal frequency, the scanamplitude for the oscillating scanners should all be less than or equalto the expected scan amplitude at the resonant frequency. All of theoscillating scanners 490, 492, 494, 496 must have a sufficient scanamplitude when operating at the drive signal frequency to perform allrequired functions such as printing and illuminating feedback sensors510, 512, 514, 516. Thus, in block 536, the drive signal amplitude foreach scanner 490, 492, 494, 496 is adjusted such that the scan amplitudeis sufficiently high for every oscillating scanner operating at thedrive signal frequency. The amount of amplitude adjustment is achievedbased on signals from the feedback sensors 510, 512, 514, 516. In thisembodiment, the drive amplitude for each of the oscillating scanners490, 492, 494 and 496 is adjusted so that each produces the same timeinterval “t-sensor” (142). Since they are all operating at the samefrequency, amplitude will now determine the time t-sensor (142) for eachcolor.

It is also desirable to have the oscillating scanners 490, 492, 494, 496scanning in phase. However, the oscillating scanners 490, 492, 494, 496that are operating at a frequency offset from their resonant frequencywill experience a phase shift when compared to an oscillating scanneroperating at its resonant frequency. Therefore, in block 538, the phaseof each drive signal is adjusted based upon the determined resonantfrequency of each oscillating scanners 490–496 and the frequency of thedrive signal such that all of the oscillating scanners 490–496 areoperating in phase. Once the phase has been adjusted, the method movesto block 539 where a determination is made as to whether a frequencyadjust event has occurred. If not, the method returns to blocks 536 and538 to adjust the amplitude and phase of the drive signals, if needed.If a frequency adjust event has occurred, the method returns to block530 and determines resonant frequencies again for the purpose ofdetermining a new drive frequency. Examples of a frequency adjust eventwould be a power reset or a determination that one of the driveamplitudes has exceeded a predetermined threshold. The process startingat block 530 is repeated to account for any changes in the resonantfrequencies that occur due to environmental factors and the passage oftime.

If the oscillating scanners 490–496 are not busy, such as may occur whena printer is not actively printing, the control circuit 498 in FIG. 36determines resonant frequency for each scanner 490–496 by moving thedrive frequency through a range around the expected resonant frequencyand determining which frequency creates the greatest scan amplitude.That frequency is the resonant frequency. Alternatively, the controlcircuit may determine resonant frequency while the oscillating scanners490–496 are busy, by simply measuring the scan amplitude. Controlcircuit 498 may calculate a new resonant frequency based upon the newlymeasured scan amplitude, and the known prior resonant frequency, prioroperating amplitude, and currently existing operating frequency. To makethis type of calculation, the control circuit must assume that thecurrently existing operating frequency remains on the same side of theresonant frequency.

The method of FIG. 37 allows oscillating scanners to be used in tandemscanners such as a color laser printer. These oscillating scanners aretypically less expensive and complicated than rotating polygonalscanners. Furthermore, the use of multiple scanners operating in tandemallows for improved accuracy in printing while maintaining a highprocess speed.

Dual Light Source Torsion Oscillator System

One application of torsion oscillator 50 is in a laser printing system94, illustrated schematically in FIG. 38. In a laser printing system 94,a photoconductor drum 96 is rotated by drive train 97 as the drumreceives light from reflected beams of light 98A and 98B through a lenssystem 99 when the reflected light beams 98A and 98B are within the scanimaging window during its sweep generated by the torsion oscillator 50as described above. The outer boundaries of the scan imaging window areillustrated by dashed lines 100 a and 100 b for reflected beam 98A andbroken lines 100 c and 100 d for reflected beam 98B. The imaging windowof the reflected beams 98A and 98B may be indirectly detected by one ormore sensors such as sensors A and B that are preferably placed adjacentto the imaging window. Drive train 97 is controlled by control logic 101along path 102 to adjust the rate of rotation of drum 96. Similarly,control logic 101 controls the light source 104 through path 106 tomodulate the light source 104. The light source 104 is preferably a duallight source providing at least two light beams 103A and 103B. In thealternative, multiple single beam light sources 104 may be used.Preferably, the reflected light beams 98A and 98B are offset one fromthe other in a direction perpendicular to the scan direction.

As the reflected light beams 98A and 98B are scanned across the lengthof the drum 96 within the boundaries of the scan operating window, scantraces are provided on the surface of the drum 96. Each scan of thereflected light beams 98A and 98B across the length of the drum producesseparate scan traces on the surface of the drum 96. By independentlymodulating the light beams 103A and 103B of the light source 104, scantraces can be provided on the surface of the drum as the reflected lightbeams 98A and 98B are scanned in one or both directions across thesurface of the drum.

Assuming the scan traces provided by reflected light beams 98A and 98Bare sufficiently close together on the surface of the drum 96, thesurface of the drum 96 can be represented by a planar approximation asillustrated in FIGS. 39 and 40. FIGS. 39 and 40 provide illustration ofmultiple scan traces on the surface of the drum 96. The separationdistance between scan traces on the surface of the drum 96 is determinedby the drum rotational speed and the oscillation frequency of theoscillator 50. A comparison of a single beam light source and a dualbeam light source is provided by comparing FIG. 39 to FIG. 40 for agiven drum 96 rotational speed and given oscillation frequency ofoscillator 50.

Referring now to FIGS. 39 and 40, an important advantage of theinvention will be described. FIG. 39 illustrates scan traces 108 on asurface such as drum 96 for a single beam oscillator and scan traces 110on a surface such as drum 96 for a dual beam oscillator according to theinvention. The scan traces 108 and 110 are for an oscillator operatingin a unidirectional mode, i.e., scan traces on the surface are providedin only one direction. Three scans of the oscillator device 50 acrossthe surface of the drum 96 are shown providing scan traces 108 and 110.A scan of the drum 96 is provided when the reflected beam 98A or 98Btraverses the length of the drum 96 from a first end to a second endthereof.

In scan traces 108, there is a separation distance A between each scantrace 111, 115 and 113 for an oscillator 50 reflecting a beam of lightfrom a single light source. In an oscillator 50 according to theinvention, two or more light sources 104 are used. The beams of light103A and 103B from the light sources 104 are imaged by lens system 99 toprovide two traces 111 a and 111 b per scan (Scan 1) having a separationdistance between the traces 111 a and 111 b of B. On the next scan, Scan2, the traces 115 a and 115 b again have the same separation distance Bbetween each trace. Also, trace 115 a in Scan 2 are displaced from trace111 b in Scan 1 by a distance C. It is preferred that the system 94 bedesigned so that distance B is substantially equal to distance C. Sincetwo traces are provided per scan in using the dual beam oscillator,separation distance A=B+C or A=2*B where B=C. Accordingly, a dual beamoscillator operating at the same frequency as a single beam oscillatorcan provide twice the number of traces per scan as a single beamoscillator. In the alternative, a dual beam oscillator can provide scantraces having spacing A between each trace when the oscillator isoperated at half the frequency of a single beam oscillator when dualbeam spacing B=A.

Operation of a single beam oscillator and a dual beam oscillator forbi-directional scanning of a surface is illustrated in FIG. 40. In thecomparison of scan traces 109 and 117, the oscillator scans the surfaceof the drum 96 in both directions. Thus, for an oscillator operating atthe same oscillation frequency as in FIG. 39, twice as many scan tracesare provided on the surface of the drum 96 rotating at the same speed asin FIG. 39. In the single beam oscillator shown in the upper part ofFIG. 40, each trace 111 is separated from trace 115 by distance B andeach trace 115 is separated from trace 113 by distance C. In this case,A=B+C, and since B=C, A=2*B. However, for a dual beam oscillatoroperating at the same frequency as a single beam oscillator, shown inthe lower part of FIG. 40, twice as many scans are provided on thesurface of a drum 96 operating at the same speed as the drum 96 in theupper part of FIG. 40. In the dual beam oscillator, traces 111 a, 115 aand 113 a are separated from traces 111 b, 115 b and 113 b a distance ofD. Traces 111 b, 115 b and 113 b are separated from traces 115 a, 113 aand 111 a, respectively a distance of E. In this case A=B+C=2*(D+E) orA=2*B=2*(D+E) or A=4*D where D=E and B=C.

As shown by comparing the upper portions of FIGS. 39 and 40, a resonantoscillator 50 operating in a bi-directional mode has twice the scanefficiency as a resonant oscillator 50 operating in a unidirectionalmode. As discussed in more detail below, the scan efficiency (η) for asingle beam oscillator operating in a unidirectional mode is about 25%.The scan efficiency (η) for a resonant oscillating scanning device isdefined as the ratio of the usable print time to the total scan time.For the same single beam oscillator operating in a bi-directional mode,the scan efficiency (η) is 50%. By comparison, the scan efficiency for arotating polygon mirror in a scanning system ranges from about 65 toabout 75%. Hence, a single beam oscillator must operate at a higherfrequency of oscillations to provide the same scanning speed even whenprinting in a bi-directional manner. Related to this problem is anassociated need for about 50% higher data rates for resonant oscillatortype scanner as compared to rotating mirror type scanner because of theshorter time window available during each scan to scan the beam acrossthe surface.

In a dual light source system 94 according to the invention, each lightbeam can be modulated separately and provided with separate video datastreams so that two separate reflected light beams 98A and 98B can beused to scan a surface essentially simultaneously. As shown bycomparison of the traces in FIGS. 39 and 40 above, a dual light sourcecan double the throughput of data of a resonant oscillator scanner, ascompared to a scanner having a single light source. Since twice theamount of data is throughput in a single scan, the increased throughputis equivalent to increasing the scan efficiency, which may becharacterized as an increase in the effective efficiency. Hence, the“effective efficiency” of a unidirectional scanning system 94 accordingto the invention is about 50% compared to 25% for a single light beamsource scanner. For bidirectional scanning, the effective efficiency ofa dual light source scanning system 94 is four times greater than for asingle light source scanner scanning in only one direction. Thus, theefficiency for a dual light source scanning system 94 according to theinvention is equivalent to a resonant scanning system having about 100%efficiency. Thus the effective efficiency is about 100%.

The previously described methods and devices may be combined with thedual beam embodiment described above and illustrated in FIG. 38. Also,the dual beam embodiment is intended to represent a multiple beamembodiment such as a three or four beam embodiment. When the dual beamembodiment is combined with the two sensor embodiment as illustrated inFIG. 38, either four or two sensors may be used. If four sensors areused, then two sensors will monitor each reflected beam 98A and 98B, andeach sensor A and B represent two sensors. If only two sensors are used,they may be used to monitor a single reflected beam, such as 98A, andthe position of the other light beam 98B will be determinedexperimentally during manufacturing and calibration. Since the relativepositions of the two beams 98A and 98B will be constant at the lightsource, the relative position of the two light beams will be predictableand relatively constant at the drum 96. By a calibration process duringmanufacturing, one may detect the relative positions of the two lightbeams 98A and 98B and correlate those two positions. Thus, by detectingthe position of one light beam with two sensors, the position of theother beam is also known through the calibration process. Also, sincethe two beams should have almost identical scan timing, they shouldarrive at the sensors A and B at almost exactly the same time. Thus, asingle sensor A and a single sensor B may be placed in the path of bothbeams 98A and 98B, and the two beams will illuminate the sensors A and Bat almost identical times, such that it creates a single signal that maybe used to monitor both beams.

When the dual beam embodiment is combined with the single sensorembodiment, one may use a single sensor, such as sensor A on eachreflected light beam, or one may use a single sensor on only one ofreflected light beams, or one may use a single sensor to detect bothbeams simultaneously. If one sensor is used to detect one beam, acalibration process is performed as discussed above in which therelative positions of the two light beams are determined and based ondetecting one light beam, the position of the other light beam may bedetermined using the calibration data.

If the manufacturing tolerances are sufficiently accurate and small, orif the application can tolerate relatively large tolerances, theposition of one beam relative to the other may be assumed rather thandetermined by a calibration process. For example, in a printingapplication, the light source 104 and lens system 99 will be designed toproduce two reflected light beams 103A and 103B that are spaced apart atthe drum by a distance that is exactly equal to the separation betweentwo print scans on the drum 96. Also, the reflected light beams 98A and98B will be assumed to produce spots on the drum 96 at positions thatare substantially aligned with the direction of travel at those spots onthe drum. For example, if the drum 96 is rotating on a horizontal axis,the reflected light beams 98A and 98B may be visualized as striking thesurface of the drum 96 at a position where the surface is traveling in avertical direction and the relative positions of the two reflected laserbeams 98A and 98B will be precisely vertical, one with respect to theother.

The same principles apply when more than two light beams are produced.Because all of the light beams are being reflected by the samereflective surface, and because the light sources produce stable lightbeams held in a constant position, one may predict the positions of allof the beams based on the position of one beam at one sensor andcalibration data or design data.

Using one sensor to control and monitor multiple light beams producesobvious cost savings as compared to using one sensor to monitor eachlight beam. Likewise, using two sensors to control and monitor multiplelight beams achieve cost savings as compared to using two sensors tomonitor each light beam.

The foregoing description of preferred embodiments has been presentedfor purposes of illustration and description. They are not intended tobe exhaustive or to limit the invention to the precise form disclosed.Obvious modifications or variations are possible in light of the aboveteachings. The embodiments are chosen and described in an effort toprovide the best illustrations of the principles of the invention andits practical application, and to thereby enable one of ordinary skillin the art to utilize the invention in various embodiments and withvarious modifications as is suited to the particular use contemplated.All such modifications and variations are within the scope of theinvention as determined by the appended claims when interpreted inaccordance with the breadth to which they are fairly, legally, andequitably entitled.

1. A method of scanning comprising: producing at least first and secondlaser beams and directing the laser beams in a desired direction;oscillating the laser beams at a frequency at or near the resonantfrequency of a mechanical system associated with the laser beams toproduce oscillating first and second laser beams that move through firstand second scan paths, respectively, each laser beam moving in a firstdirection and a second direction, the second direction being generallyin the opposite direction to the first direction, and directing thelaser beams toward at least one target surface to produce at least firstand second scan lines on the target surface.
 2. The method of claim 1further comprising the step of detecting at least one of the first andsecond laser beams with at least one sensor to determine the times atwhich the detected laser beam appears at a first location.
 3. The methodof claim 1 further comprising the step of detecting at least one of thefirst and second laser beams with a single sensor to determine the timesat which the detected laser beam appears at a first location.
 4. Themethod of claim 1 further comprising the step of detecting both thefirst and second laser beams with a single sensor to determine that thetimes at which the first and second laser beams appear at a firstlocation.
 5. The method of claim 1 further comprising the step ofdetecting at least one of the first and second laser beams with firstand second sensors to determine the times at which the detected laserbeam appears at a first location and a second location.
 6. The method ofclaim 1 further comprising the step of detecting both of the first andsecond laser beams with first and second sensors to determine the timesat which the first and second laser beams appear at a first location anda second location.
 7. The method of claim 1 further comprising the stepof detecting the first laser beam with first and second sensors anddetecting the second laser beam with third and fourth sensors todetermine the times at which the first laser beam appears at first andsecond locations and to determine the times at which the second laserbeam appears at third and fourth locations.
 8. The method of claim 1further comprising producing a plurality of laser beams, said pluralitybeing greater than two.
 9. The method of claim 1 further comprising thesteps of: detecting at least one of the first and second laser beamswith at least one sensor to determine the times at which the detectedlaser beam appears at a first location; determining the direction oftravel of the detected laser beam based upon the times at which thedetected laser beam appears at the first location.
 10. The method ofclaim 1 further comprising the steps of: detecting at least one of thefirst and second laser beams with at least one sensor to determine thetimes at which the detected laser beam appears at a first location;determining the direction of travel of the detected laser beam basedupon the times at which the detected laser beam appears at the firstlocation; determining the time interval during which the first andsecond laser beams are traveling across an imaging window based upon thetimes at which the detected laser beam appears at the first location;and modulating the first and second laser beams to produce imaging dataon the imaging window.